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Full text of "NB NBIC 3 (2007): 2008 Addendum to Part 3"

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NOTICE OF INCORPORATION 

United States Legal Document 

J^" All citizens and residents are hereby advised that 
this is a legally binding document duly incorporated by 
reference and that failure to comply with such 
requirements as hereby detailed within may subject you 
to criminal or civil penalties under the law. Ignorance of 
the law shall not excuse noncompliance and it is the 
responsibility of the citizens to inform themselves as to 
the laws that are enacted in the United States of America 
and in the states and cities contained therein. "^& 

* * 

NBIC 2007, National Board Inspection Code, 
Part 3, Repair and Alteration, 2008 Addenda, 
as mandated by the requirements of the States 
of Alabama, Alaska, Arizona, Colorado, Iowa, 
Kansas, Michigan, Missouri, Nebraska, New Jersey, 
North Dakota, Ohio, Oregon, and Utah. 






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■ H E 

Natidnai 
Board 

□ f Boiler and 
Pressure Vessel 
Inspectors 




National 

Board 

Inspection 

Code 



Part 3 - Repairs and Alterations 



NATIONAL BOARD INSPECTION CODE 



NOTE: Pages ii through xvi are not part of this 
American National Standard 



Library of Congress Catalog Card No. 52-44738 

Printed in the United States of America 

All Rights Reserved 

©2008 
The National Board of Boiler and Pressure Vessel Inspectors 

Headquarters 

1 055 Crupper Avenue 

Columbus, Ohio 43229-1183 

614.888.8320 

614.847.1828 Fax 

Testing Laboratory 

7437 Pingue Drive 

Worthington, Ohio 43085-1 715 

614.888.8320 

614.848.3474 Fax 

Training & Conference Center 

1065 Crupper Avenue 

Columbus, Ohio 43229-1 1 83 

614.888.8320 

614.847.5542 Fax 

Inspection Training Center 

1 075 Crupper Avenue 

Columbus, Ohio 43229-1 183 

614.888.8320 

614.847.5542 Fax 



NATIONAL BOARD INSPECTION CODE 



The National Board of Boiler and Pressure Vessel Inspectors 
Board of Trustees 

R.J. Aben Jr. 
Chairman 

M. Mooney 
First Vice Chairman 

J .T. Amato 
Second Vice Chairman 

D.A. Douin 
Secretary/Treasurer 

J.M. Given Jr. 
Member at Large 

D.J. Jenkins 
Member at Large 

D.C. Price 
Member at Large 

B. Krasiun 
Member at Large 

Advisory Committee 

G. W. Galanes 
representing welding industries 

E.J. Hoveke 
representing National Board certificate holders 

L.J. McManamon Jr. 
representing organized labor 

G. McRae 
representing pressure vessel manufacturers 

B.R. Morelock 
representing boiler and pressure vessel users 

C.E. Perry 
representing boiler manufacturers 

C.G. Schaber 
representing authorized inspection agencies (insurance companies) 



NATIONAL BOARD INSPECTION CODE 



National Board Members 

Alabama Ralph P. Pate 

Alaska Chris Fulton 

Arizona Randall 0. Austin 

Arkansas Gary R. Myrick 

California Donald C. Cook 

Colorado Steve Nelson 

Connecticut Allan E. Piatt 

Delaware James B. Harlan 

Tlorida Michael A. Burns 

Georgia Earl Everett 

Hawaii Keith A. Rudolph 

Idaho Michael Poulin 

Illinois 

Indiana Daniel Willis 

Iowa Michael Klostcrman 

Kansas Donald J. Jenkins 

Kentucky Rodney Handy 

Louisiana William Owens 

Maine John H. Burpee 

Maryland Karl J. Kraft 

Massachusetts Mark Mooney 

Michigan Robert J. Aben Jr. 

Minnesota Joel T. Amato 

Mississippi Kenneth L. Watson 

Missouri Gary Scribner 

Montana Timothy Stewart 

Nebraska Christopher B. Cantrell 

Nevada Roy Perry 

New Hampshire Wayne Brigham 

New Jersey Milton Washington 

New York Peter L. Vescio 

North Carolina Jack M. Given Jr. 

North Dakota Robert Reetz 

Ohio DeanT. Jagger 

Oklahoma Tom Monroe 

Oregon Michael D. Graham 

Pennsylvania Jack A. Davenport 

Rhode Island Benjamin Anthony 

South Dakota Howard D. Pfaff 

Tennessee Audrey E. Rogers 

Texas Anthony P. Jones 

Utah Rick Sturm 

Vermont Wesley E. Criderjr. 

Virginia Edward G. Hilton 

Washington Linda Williamson 

West Virginia 

Wisconsin Michael |. Verhagen 

Chicago, IL Michael J. Ryan 

Detroit, Ml John E. Bell 

Los Angeles, CA Jovie Aclaro 

Milwaukee, Wl Randal S. Pucek 

New York, NY William McGivney 

Alberta Ken K.I. Lau 

British Columbia John G. Siggers 

Manitoba Terry W Rieger 

New Brunswick Dale E. Ross 

Newfoundland & Labrador E. Dennis Eastman 

Northwest Territories Steve Donovan 

Nova Scotia Peter Dodge 

Nunavut Territory 

Ontario Frantisek Musuta 

Prince Edward Island Kenneth Hynes 

Quebec Madiha M. Kotb 

Saskatchewan Brian Krasiun 

Yukon Territory Daniel C. Price 



NATIDNAL BOARD INSPECTION CODE 



National Board inspection Code Committees 



Main Committee 



T. Parks, Chair 

The National Board of Boiler and 

Pressure Vessel Inspectors 


J. Pillow 

Common Arc Corporation 


R. Wielgoszinski, Vice Chair 
Hartford Steam Boiler Inspection and 
Insurance Company of Connecticut 


A. Piatt 

State of Connecticut 


R. 1 lough, Secretary 

The National Board of Boiler and 

Pressure Vessel Inspectors 


R. Reetz 

State of North Dakota 


R. Aben 

State of Michigan 


H. Richards 
Southern Company 


S. Bacon 
Conoco Phillips 


J. Richardson 
Consultant-Dresser Inc. 


P. Bourgeois 
Travelers 


C. Scribner 
5(<afe of Missouri 


D. Canonico 
Canonico & Associates 


J. Sckoly 

Wayne Grouse Inc. 


D. Cook 

State of California 


R. Snvder 
ARISE, Inc. 


P. Edwards 

Stone & Webster, Inc. 


S. Staniszewski 

US Department of Transportation 


C. Calanes 

Midwest Generation EME, LLC 


R. Sulzer 

The Babcock & Wilcox Company 


J. Given 

State of North Carolina 


H. liter 

MIRANT Mid-Atlantic 


F. Hart 

Furmanite Corporation 


). Yagen 
Dynegy, Inc. 


C. Hopkins 
Seattle Boiler Works 




D. Parrish 
TM Global 





NATIDNAL BOARD INSPECTION CODE 



Subcommittee for Installation (Part 1) 



H. Richards, Chair 
Southern Company 


A. Plall 

State of Connecticut 


C. Hopkins 
Seattle Boiler Works 


G. Scribner 
State of Missouri 


P. Bourgeois 
St. Paul Travelers 


R. Snyder 
ARISE, Inc. 


C. Halley 
ABMA 


R. Sulzor 

The Babcock and Wilcox Company 


S. Konopacki 
Midwest Generation 


H. Titer 

MIRANT Mid-Atlantic 


B. Moore 

Hartford Steam Boiler Inspection 


J. Yagen 
Dynegy, Inc. 



Subgroup for Installation (Part 1) 



Boilers 




Pressure Vessels and Piping 


C. Hopkins, Chair 
Seattle Boiler Works 




). Yagen, Chair 
Dynegy, Inc. 


P. Bourgeois 
St. Paul Travelers 




H. Richards 
Southern Company 


C. Halley 
ABMA 




C. Scribner 
State of Missouri 


S. Konopacki 
Midwest Generation 




R. Snyder 
ARISE, Inc. 


B. Moore 

Hartford Steam Boiler 


Inspection 


H. Titer 

MIRANT Mid-Atlantic 


A. Piatt 

State of Connecticut 






C. Scrihner 
State of Missouri 






R. Sulzer 

The Babcock & Wilcox 


Company 





NATIONAL BOARD INSPECTION CODE 



Subcommittee for Inspection (Part 2) 



D. Cook, Chair 
Slate of California 


D. Parrish 
FM Global 


S. Bacon 

Conoco Phillips-Ferndale Refinery 


R. Reetz 

State of North Dakota 


B. Barbato 

St. Paul Travelers 


J. Richardson 
Consultant-Dresser, Inc. 


D. Canonico 
Canonico & Associates 


J. Riley 

Chevron Energy and Technology 


J. Getter 
Worthinglon Cylinders 


M. Schwartzwalder 
ATP 


P. Martin 

The United Association of journeymen and Apprentices 

of the plumbing and P'pe Filling industry of lite United Slates and Canada 


R. Shapiro 
PacifiCorp 


G. McRae 

Trinity Industries, Inc. 


S. Staniszewski 

US Department of Transportation 


V. Newton 
Chubb & Son 


R. Wacker 
Dupont 



Subgroup for Inspection (Part 2) 



General Requirements 


Specific Requirements 


J. Getter, Chair 
Worthington Cylinders 


S. Staniszewski 

US Department of Transportation 


D. Canonico 
Canonico & Associates 


S. Bacon 

Conoco Phillips- Ferndale Refinery 


R. Dobbins 
Zurich N.A. 


B. Barbato 

St. Paul Travelers 


M. Horbaczcwski 
Midwest Generation 


D. Cook 

Stale: o( California 


P. Martin 

The United Association of journeymen and Apprentices 

o f '.hi fiumbing and t'ipe fi'.l'ng industry of li;e United SUtes and Canada 


R. Dobbins 
Zurich N.A. 


D. Parrish 
FM Global 


). Getter 
Worthington Cylinders 


J. Richardson 
Consultant-Dresser, Inc. 


G. McRae 

Trinity Industries, Inc. 


R. Shapiro 
PacifiCorp 


J. Riley 

Chevron Energy and Technology 




M. Schwartzwalder 
AEP 




R. Wacker 
Dupont 



NATIONAL BDARD INSPECTION CODE 



Subcommittee for Repairs and Alterations (Part 3) 


C. Calanes, Chair 

Midwest Generation EME, LLC' 




F. Pavlovicz 

The Babcock and Wilcox Company 


R. Abcn 

State of Michigan 




J. Pillow -Vice Chair 
Common Arc. Corporation 


P. Edwards 

Stone & Webster, Inc. 




B. Schulte 
NRC lexas, U> 


|. Given 

5tafe of North Carolina 




J. Sekcly 

Wayne Crouse Inc. 


). Larson 

OneBeacon America Insurance 


Company 


M. Webb 
Xcel Energy 



Subgroup for Repairs and Alterations (Part 3) 



General Requirements 

P. Edwards, Chair 
Stone & Webster, Inc. 

R. Aben 

State of Michigan 

J. Larson 

OneBeacon America Insurance Company 

R. Pulliam 

The Babcock & Wilcox Company 

B. Schulte 
NRC Texas, LP 

M. Webb 
Xcel knergy 



Specific Req u ire ments 

J. Sokcly, Chair 
Wayne Crouse Inc. 

G. Galancs 

Midwest Generation EME, LLC 

J. Given 

Slate of North Carolina 

W. Jones 
ARISE, Inc. 

F. Pavlovicz 

The Babcock & Wilcox Company 

J. Pillow 

Common Arc Corporation 



NATIONAL BOARD INSPECTION CODE 



Subcommittee for Pressure Relief Devices (Parts 1, 2, and 3) 



F. I lart. Chair 
rurmanilc America Inc. 


R. Donalson 

iyco Valves and Controls 


A. Cox 
Industrial Value 


K. Fitzimmons 
Carter Chambers, LLC 


J. Ball 

The National Board of Boiler and 

Pressure Vessel Inspectors 


G. Humphtries 
Oxy Vinyls, LP 


M. Brodeur 

International Valve & Instr. Corp. 


R. McCaffrey 
Quality Valve 


S. Cammeresi 
CCR 


T. Patel 

Tarris Engineering 


D. DeMichael 
DuPont 





Special Subgroups for Installation, Inspection, and Repairs and Alterations (Parts 1, 2, and 3) 



Locomotive Boilers 






B. Withuhn, Chair 
Smithsonian Institution 




S. loo 

Union Pacific Railroad 


S. Butler 

Midwest Locomotive & 

Works 


Machine 


D. McCormack 
Consultant t 


D. Conrad 

Valley Railroad Co. 




L. Moedinger 
Stra.shurg Railroad 


R. Tran/en 

Steam Services of America 




R. Rcetz 

State of North Dakota 


D. Griner 

Wasatch Railroad Contractors 


G. Scerbo 

Federal Railroad Administration 


S. Jackson 
D & SNC 




R. Schueler 

The National Board of Boiler andPres- 

surc Vessel Inspectors 


M. Janssen 

Vapor Locomotive Compar 


y 


R. Stone 

ABB/Combustion Engineering 

R.Yuill 
Consultant 



NATIONAL BOARD INSPECTION CODE 



Spe cial Subgro ups for install ation, Inspection , and Repairs and Alterations (Pa rts 1, 2, and 3) 

Graphite 

E. Saltow, Chair 

SCL Carbon Croup/SCL Technic 



W. Banker 
Graphite Repairs, Inc 

F. Brown 

I he National Board of Boiler and 

Pressure Vessel Inspectors 

K. Cummins 
Louisville Graphite 

S. Malone 
Carbone of America 

M. Minick 
FM Global 

A. Stupica 

SCL Carbon Croup/SCL Technic 



Fiber-Reinforced Pre ssure Vessels 

B. Shelley, Chair 
DuPont 

K Brown 

The National Board of Boiler and 

Pressure Vessel Inspectors 

J. Bustillos 

Bustillos and Consultants 



D. Eisberg 

Energy Recovery Inc. 

I. Fovvlor 
Retired/Spicewood, TX 

D. Keeler 

The Dow Chemical Company 

R. Lewandowski 

Corrosion Resistant Composites 

I I. Marsh 
Consultant 

D. Pinell 
ARSIS 

I. Richter 

FEMcch engineering 



NATIONAL BOARD INSPECTION CODE 



National Board Inspection Code 
2007 Edition including 2008 Addendum 

Date of Issue — December 31, 2008 

This code was developed under procedures accredited as meeting the criteria for American 
National Standards. The Consensus Committee that approved the code was balanced to ensure 
that individuals from competent and concerned interests had an opportunity to participate. The 
proposed code was made available for public review and comment, which provided an 
opportunity for additional public input from industry, acadcmia, regulatory and jurisdictional 
agencies, and the public-at-large. 

The National Board does not "approve," "rate," or "endorse" any item, construction, 
proprietary device, or activity. 

The National Board does not take any position with respect to the validity of any patent rights 
asserted in connection with any items mentioned in this document, and does not undertake 
to insure anyone utilizing a standard against liability for infringement of any applicable Letters 
Patent, nor assume any such liability. Users of a code are expressly advised that determination 
of the validity of any such patent rights, and the risk of infringement of such rights, is entirely 
their own responsibility. 

Participation by federal agency representative(s) or person(s) affiliated with industry is not to be 
interpreted as government or industry endorsement of this code. 

The National Board accepts responsibility for only those interpretations issued in accordance 
with governing National Board procedures and policies which preclude the issuance of 
interpretations by individual committee members. 

The footnotes in this document are part of this American National Standard. 



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W 



The above National Board symbols are registered with the US Patent Office. 

"National Board" is the abbreviation for The National Board of Boiler and Pressure Vessel 
Inspectors. 

No part of this document may be reproduced in any form, in an electronic retrieval system or 
otherwise, without the prior written permission of the publisher. 



NATIONAL BOARD INSPECTION CODE 



XII 



NATIONAL BOARD INSPECTION CODE 



Foreword 

The National Board of Boiler and Pressure Vessel Inspectors is an organization comprised of 
Chief Inspectors for the states, cities, and territories of the United States and provinces and 
territories of Canada. It is organized for the purpose of promoting greater safety to life and 
property by securing concerted action and maintaining uniformity in post-construction 
activities of pressure-retaining items, thereby ensuring acceptance and interchangeability 
among jurisdictional authorities responsible for the administration and enforcement of various 
codes and standards. 

In keeping with the principles of promoting safety and maintaining uniformity the National 
Board originally published The NBIC in 1 946, establishing rules for inspection and repairs to 
boilers and pressure vessels. The National Board Inspection Code (NBIC) Committee is charged 
with the responsibility for maintaining and revising the NBIC. In the interest of public safety, 
the NBIC Committee decided, in 1 995, to revise the scope of the NBIC to include rules for 
installation, inspection, and repair or alteration to boilers, pressure vessels, piping, and 
nonmetallic materials. 

In 2007, the NBIC was restructured into three Parts specifically identifying important post- 
construction activities involving safety of pressure-retaining items. This restructuring provides for 
future expansion, transparency, and uniformity, ultimately improving public safety. 

The NBIC Committee's function is to establish rules of safety governing post-construction activities 
for the installation, inspection and repair and alteration of pressure-retaining items, and to interpret 
these rules when questions arise regarding their intent. In formulating the rules, the NBIC 
Committee considers the needs and concerns of individuals and organizations involved in the 
safety of pressure-retaining items. The objective of the rules is to afford reasonably certain 
protection of life and property, so as to give a reasonably long, safe period of usefulness. 
Advancements in design and material and the evidence of experience are recognized. 

The rules established by the NBIC Committee are not to be interpreted as approving, 
recommending, or endorsing any proprietary or specific design, or as limiting in any way an 
organization's freedom to choose any method that conforms to the NBIC rules. 

The NBIC Committee meets regularly to consider revisions of existing rules, formulation of new 
rules, and respond to requests for interpretations. Requests for interpretation must be addressed 
to the NBIC Secretary in writing and must give full particulars in order to receive Committee 
consideration and a written reply. Proposed revisions to the Code resulting from inquiries will 
be presented to the NBIC Committee for appropriate action. 

Proposed revisions to the Code approved by the NBIC Committee are submitted to the 
American National Standards Institute and published on the National Board Web site to 
invite comments from all interested persons. After the allotted time for public review and final 
approval, revisions are published annually in Addenda to the NBIC. 

Organizations or users of pressure-retaining items are cautioned against making use of 
revisions that are less restrictive than former requirements without having assurance that they 
have been accepted by the Jurisdiction where the pressure-retaining item is installed. 



NATIONAL BDARD INSPECTION CODE 



The general philosophy underlying the NBIC is to parallel those provisions of the original code 
of construction, as they can be applied to post-construction activities. 

The NBIC does not contain rules to cover all details of post-construction activities. Where 
complete details are not given, it is intended that individuals or organizations, subject to the 
acceptance of the Inspector and Jurisdiction when applicable, provide details for post- 
construction activities that will be as safe as otherwise provided by the rules in the original 
Code of Construction. 

Activities not conforming to the rules of the original code of construction or the NBIC must 
receive specific approval of the Jurisdiction, who may establish requirements for design, 
construction, inspection, testing, and documentation. 

There are instances where the NBIC serves to warn against pitfalls; but the Code is not a hand- 
book, and cannot substitute for education, experience, and sound engineering judgment. 

It is intended that this Edition of the NBIC and any subsequent Addenda not be retroactive. 
Unless the Jurisdiction imposes the use of an earlier edition, the latest effective edition and 
addenda is the governing document. 



XIV 



NATIONAL BOARD INSPECTION CODE 



Introduction 

It is the purpose of the National Board Inspection Code (NBIC) to maintain the integrity of 
pressure-retaining items by providing rules for installation, and after the items have been 
placed into service, by providing rules for inspection and repair and alteration, thereby 
ensuring that these items may continue to be safely used. 

The NBIC is intended to provide rules, information and guidance to manufacturers, 
Jurisdictions, inspectors, owner-users, installers, contractors, and other individuals and 
organizations performing or involved in post-construction activities, thereby encouraging the 
uniform administration of rules pertaining to pressure-retaining items. 

Scope 

The NBIC recognizes three important areas of post-construction activities where information, 
understanding, and following specific requirements will promote public and personal safety. 
These areas include: 

• Installation 

• Inspection 

• Repairs and Alterations 

The NBIC provides rules, information, and guidance for post-construction activities, but does 
not provide details for all conditions involving pressure-retaining items. Where complete de- 
tails are not provided in this Code, the Code user is advised to seek guidance from the Jurisdic- 
tion and from other technical sources. 

The words shall, should, and may are used throughout the NBIC and have the following intent: 

• Shall - action that is mandatory and required. 

• Should - indicates a preferred but not mandatory means to accomplish the requirement 
unless specified by others such as the Jurisdiction. 

® May - permissive, not required or a means to accomplish the specified task. 

Organization 

The NBIC is organized into three Parts to coincide with specific posl-construction activities 
involving pressure-retaining items. Each Part provides general and specific rules, information, 
and guidance within each applicable post-construction activity. Other NBIC Parts or other 
published standards may contain additional information or requirements needed to meet the 
rules of the NBIC. Specific references are provided in each Part to direct the user where to find 
this additional information. NBIC Parts are identified as: 

• Part 1 , Installation - This Part provides requirements and guidance to ensure all types of 
pressure-retaining items are installed and function properly. Installation includes 
meeting specific safety criteria for construction, materials, design, supports, safety 
devices, operation, testing, and maintenance. 

® Part 2, Inspection -This Part provides information and guidance needed to perform and 
document inspections for all types of pressure-retaining items. This Part includes 
information on personnel safety, non-destructive examination, tests, failure 
mechanisms, types of pressure equipment, fitness for service, risk-based assessments, 
and performance based standards. 



NATIONAL BOARD INSPECTION CODE 



• Part 3, Repairs and Alterations -This Part provides information and guidance to 
perform, verify, and document acceptable repairs or alterations to pressure-retaining 
items regardless of code of construction. Alternative methods for examination, testing, 
heat treatment, etc., are provided when the original code of construction requirements 
cannot be met. Specific acceptable and proven repair methods are also provided. 

Each NBIC Part is divided into major Sections as outlined in the Table of Contents. 

Tables, charts, and figures provide relevant illustrations or supporting information for text 
passages, and are designated with numbers corresponding to the paragraph they illustrate or 
support within each Section. Multiple tables, charts, or figures referenced by the same 
paragraph will have additional letters reflecting the order of reference. Tables, charts, and 
figures are located in or after each major Section within each NBIC Part. 

Text Identification and Numbering 

Each page in the text will be designated in the top header with the publication's name, part 
number, and part title. The numbering sequence for each section begins with the section 
number followed by a dot to further designate major sections (e.g., 1.1,1 .2, 1 .3). Major 
sections are further subdivided using dots to designate subsections within that major section 
(e.g., 1.1.1, 1.2.1, 1.3.1). Subsections can further be divided as necessary. 

Paragraphs under sections or subsections shall be designated with small letters in parenthesis 
(e.g., a), b), c)) and further subdivided using numbers in parenthesis (e.g., 1), 2), 3)). 
Subdivisions of paragraphs beyond this point will be designated using a hierarchical sequence 
of letters and numbers followed by a dot. 

Example: 2.1 Major Section 

2.1.1 Section 

2.1.2 Section 

2.1.2. Subsection 

a) paragraph 

b) paragraph 

1 ) subparagraph 

2) subparagraph 

a. subdivisions 

1. subdivisions 

2. subdivisions 

b. subdivisions 

1 . subdivisions 

2. subdivisions 

Tables and figures will be designated with the referencing section or subsection identification. 
When more than one table or figure is referenced in the same section or subsection, letters or 
numbers in sequential order will be used following each section or subsection identification. 



NATIONAL BOARD INSPECTION CODE 



Supplements 

Supplements are contained in each Pari of the NBIC to designate information only pertaining to 
a specific type of pressure-retaining item (e.g., Locomotive Boilers, Historical Boilers, Graphite 
Pressure Vessels.) Supplements follow the same numbering system used for Ihe main text only 
preceded by the Letter "S." Each page of the supplement will identify the supplement number 
and name in the top heading. 



Addenda 

Addenda, which include revisions and additions to this Code, are published annually. Addenda 
are permissive on the date issued and become mandatory six months after the date of issue. 
The addenda will be sent automatically to purchasers of the Code up to the publication of the 
next edition. Every three years the NBIC is published as a new edition that includes that year's 
addenda. 



Interpretations 

On request, the NBIC Committee will render an interpretation of any requirement of this Code. 
Interpretations are provided for each Part and are specific to the Code edition and addenda 
referenced in the interpretation. Interpretations provide information only and are not part of 
this Code. 



Jurisdictional Precedence 

Reference is made throughout this Code to the requirements of the "Jurisdiction." Where any 
provision herein presents a direct or implied conflict with any jurisdictional regulation, the 
jurisdictional regulation shall govern. 



Units of Measurement 

Both U.S. customary units and metric units are used in the NBIC. The value stated in U.S. custom- 
ary units or metric units are to be regarded separately as the standard. Within the text, the met- 
ric units are shown in parentheses. In supplement 6, Continued Service and Inspection of DOT 
Transport Tanks, the metric units are shown first with the U.S. customary units shown in parentheses. 

U.S. customary units or metric units may be used with this edition of the NBIC, but one system 
of units shall be used consistently throughout a repair or alteration of pressure-retaining items. 
It is the responsibility of National Board accredited repair organizations to ensure the 
appropriate units are used consistently throughout all phases of work. This includes materials, 
design, procedures, testing, documentation, and stamping. The NBIC policy for metrication is 
outlined in each part of the NBIC. 



Accreditation Programs 

The National Board administers and accredits three specific repair programs' as shown below: 

"R" Repairs and Alterations to Pressure-Retaining Items 

"VR" Repairs to Pressure ReliefValvcs 



1 Caution, some Jurisdictions may independently administer a program of authorization for organizations to perform repairs and 
alterations within that Jurisdiction. 



XVI 



NATIONAL BOARD INSPECTION CODE 



"NR" Repair and Replacement Activities for Nuclear Items 

Part 3, Repairs and Alterations, of the NBIC describes the administrative requirements for the 
accreditation of these repair organizations. 

The National Board also administers and accredits four specific inspection agency programs as 
shown below: 

New Construction 

Criteria for Acceptance of Authorized Inspection Agencies for New Construction 

(NB-360) 
Inservice 

Qualifications and Duties for Authorized Inspection Agencies (AlAs) Performing Inservice 

Inspection Activities and Qualifications for Inspectors of Boilers and Pressure Vessels 

(NB-369) 
Owner-User 

Accreditation of Owner-User Inspection Organizations (OUIO) (NB-371 ) Owners or users 

may be accredited for both a repair and inspection program provided the requirements 

for each accreditation program are met. 
Federal Government 

Qualifications and Duties for federal Inspection Agencies Performing Inservice Inspection 

Activities (FIAs) (NIB-390) 



These programs can be viewed on the National Board Web site. For questions or further infor- 
mation regarding these programs contact: 

The National Board of Boiler and Pressure Vessel Inspectors 

1055 Crupper Avenue 

Columbus, OH 43229-1 183 

Phone-- 614.888.8320 

Fax — 614.847.1828 

Web site — www.nationalboard.org 



Certificates of Authorization for Accreditation Programs 

Any organization seeking an accredited program may apply to the National Board to obtain a 
Certificate of Authorization for the requested scope of activities. A confidential review shall be 
conducted to evaluate the organization's quality system. Upon completion of the evaluation, 
a recommendation will be made to the National Board regarding issuance of a Certificate of 
Authorization. 

Certificate of Authorization scope, issuance, and revisions for National Board accreditation 
programs are specified in the applicable National Board procedures. When the quality system 
requirements of the appropriate accreditation program have been met, a Certificate of 
Authorization and appropriate National Board symbol stamp shall be issued. 



XVIII 




Part 3 — Repairs and Alterations 



All charts, graphs, tables, and other criteria that have been 
reprinted from the ASME Boiler and Pressure Vessel Code, 
Sections I, IV, VIII, and X are used with the permission of 
the American Society of Mechanical Engineers. All Rights 
Reserved. 



NATIDNAL BOARD INSPECTION CODE • PART 3 — REPAIRS AND ALTERATIONS 

PART 3 — REPAIRS AND ALTERATIONS 

TABLE OF CONTENTS 

National Board Contact Information II 

NB Board of Trustees /Advisory Committee Members Ill 

National Board Members V 

NBIC Committee Structure VI 

National Board Inspection Code Edition /Addendum XI 

Foreword XII 

Introduction XIV 

Section 1 General and Administrative Requirements 13 

1.1 Scope 14 

1 .2 Construction Standards for Pressure-Retaining Items 14 

1 .3 Inspector 15 

1 .3.1 Authorization 15 

1.3.2 Acceptance Inspection 15 

1 .4 Definitions Relating to Pressure Relief Devices 1 5 

1 .5 Accreditation 15 

1 .5.1 Accreditation Process 16 

1 .5.2 Scope Issuance and Revision to a Quality System 1 6 

1 .6 Accreditation of "R" Repair Organizations 1 6 

1.6.1 Scope 16 

1 .6.2 Prerequisites for Issuing a National Board 

Certificate of Authorization 1 7 

1 .6.3 Procedure for Obtaining or Renewing a National Board 

Certificate of Authorization 1 7 

1 .6.4 National Board "R" Symbol Stamp 1 8 

1.6.5 Quality System 19 

1 .6.5.1 Outline of Requirements for a Quality System 

for Qualification For the National Board "R" 

Certificate of Authorization 1 9 

1 .7 Accreditation of "VR" Repair Organizations 21 

1.7.1 Scope 21 

1 .7.2 Jurisdictional Participation 21 

1.7.3 General Rules 22 

1 .7.4 Repair of Nuclear Valves 22 

1 .7.5 Issuance and Renewal of the "VR" Certificate of Authorization 22 

1 .7.5.1 General 22 

1 .7.5.2 Issuance of Certificate 22 

1 .7.5.3 Renewal of Certificate 22 

1 .7.5.4 Review of Applicant's Facility 23 

1 .7.5.5 Verification Testing 23 

1 .7.5.6 Verification Testing Alternatives 24 

1.7.6 Use of the "VR" Authorization 24 

1 .7.6.1 Technical Requirements 24 

1.7.6.2 Stamp Use 25 

2 



NATIONAL BOARD INSPECTION CODE • PART 3 — REPAIRS AND ALTERATIONS 



1.7.6.3 Return of Stamp 25 

1.7.6.4 Multiple Locations 25 

1.7.6.5 Certificate of Authorization Contents 25 

1 .7.6.6 Changes to Certificates of Authorization 25 

1 .7.6.7 Issuance of More Than One "VR" Symbol Stamp to a 
Certificate of Authorization Holder 25 

1.7.7 Quality System 25 

1 .7.7.1 General 25 

1.7.7.2 Written Description 26 

1.7.7.3 Review 26 

1 .7.7.4 Maintenance of Controlled Copy 26 

1 .7.7.5 Outline of Requirements for a Quality System 26 

1 .7.8 ASME "V," "HV," or "UV" Certificate Holders ....'. 29 

1 .8 "NR" Accreditation Requirements 30 

1.8.1 Scope 30 

1 .8.2 Prerequisites for Issuing a National Board "NR" Certificate of 
Authorization 30 

1 .8.3 Procedures for Obtaining or Renewing a National Board "NR" 
Certificate of Authorization 31 

1 .8.4 National Board "NR" Symbol Stamp 33 

1.8.5 Quality System Program 33 

1 .8.5.1 Outline of Requirements for a Quality System 

Program for Qualification for the National Board 

"NR" Symbol Stamp 33 

1 .8.6 Interface with the Owners Repair / Replacement Program 40 

Section 2 Welding and Heat Treatment 41 

2.1 Scope 42 

2.2 Welding 42 

2.2.1 Welding Procedure Specifications 42 

2.2.2 Standard Welding Procedure Specifications 42 

2.2.3 Performance Qualification 42 

2.2.4 Welding Records 42 

2.2.5 Welders' Identification 42 

2.2.6 Welders' Continuity 43 

2.3 Standard Welding Procedure Specifications 43 

2.4 AWS Reference Standards 49 

2.5 Heat Treatment 49 

2.5.1 Preheating 49 

2.5.2 Postweld Heat Treatment (PWHT) 51 

2.5.3 Alternative Welding Methods Without Postweld Heat Treatment 52 

2.5.3.1 Welding Method 1 53 

2.5.3.2 Welding Method 2 53 

2.5.3.3 Welding Method 3 55 

2.5.3.4 Welding Method 4 56 

2.5.3.5 Welding Method 5 57 

Section 3 Requirements for Repairs and Alterations 59 

3.1 Scope 60 

3.2 General Requirements for Repairs and Alterations 60 

3.2.1 Material Requirements for Repairs and Alterations 60 

3.2.2 Replacement Parts 60 

3.2.3 Drawings 61 

3.2.4 Design Requirements for Repairs and Alterations 61 

3.2.5 Calculations 62 

3 



NATIONAL BOARD INSPECTION CODE • PART 3 — REPAIRS AND ALTERATIONS 



Repairs to Pressure-Retaining Items 62 

3.3.1 Defect Repairs 62 

3.3.2 Routine Repairs 62 

3.3.3 Examples of Repairs 62 

3.3.4 Repair Methods 63 

3.3.4.1 Scope 63 

3.3.4.2 Defect Repairs 64 

3.3.4.3 Wasted Areas 66 

3.3.4.4 Seal Welding 70 

3.3.4.5 Re-Ending or Piecing Pipes or Tubes 71 

3.3.4.6 Patches 72 

3.3.4.7 Stays 74 

3.3.5 Repair of ASME Section VIII, Division 2 or 3, Pressure Vessels 74 

3.3.5.1 Scope 74 



.5..5..T. 



? 



Repair Plan 74 

3.4 Alterations 74 

3.4.1 Re-Rating 74 

3.4.2 Alterations Based on Allowable Stress Values 75 

3.4.3 Examples of Alterations 75 

3.4.4 Alteration of ASME Code Section VIII, Division 2 or 3, 

Pressure Vessels 76 

3.4.4.1 Alteration Plan 76 

Section 4 Examination andTesting 77 

4.1 Scope 78 

4.2 Nondestructive Examination 78 

4.3 Pressure Gages, Measurement, Examination, and Test Equipment 78 

4.4 Examination and Test for Repairs and Alterations 78 

4.4.1 Test or Examination Methods Applicable to Repairs 79 

4.4.2 Test or Examination Methods Applicable to Alterations 80 

4.5 Pressure Relief Valve Performance Testing andTesting Equipment 81 

4.5.1 Test Medium and Testing Equipment 81 

4.5.2 Owner-User ASME Code Section VIII Steam Testing 82 

4.5.3 Lift Assist Testing 82 

4.5.4 Pressure Test of Parts 82 

Section 5 Certification / Documentation and Stamping 85 

5.1 Scope 86 

5.2 Documentation 86 

5.2.1 Preparation of Form R-1 (Repairs) 86 

5.2.2 Preparation of Form R-2 (Alterations) 86 

5.3 Distribution of Form R-1 87 

5.4 Distribution of Form R-2 87 

5.5 Registration of "R" Forms - General 87 

5.5.1 Registration for Repairs 87 

5.5.2 Registration for Alterations 87 

5.5.3 Registration for Fiber-Reinforced Vessels 87 

5.5.4 Registration for Nuclear Repair/Replacement Activities 87 

5.5.5 Registration for Graphite Vessels 88 

5.6 Form "R" Log 88 

5.7 Stamping Requirements for Repairs and Alterations 88 

5.7.1 General 88 

5.7.2 Stamping Requirements for Repairs 88 

5.7.3 Stamping Requirements for Alterations 88 

5.8 Removal of Original Stamping or Nameplate 88 



NATIONAL BOARD INSPECTION CODE • PART 3 — REPAIRS AND ALTERATIONS 



5.9 Stamping Requirements for Pressure Relief Devices 89 

5.9.1 Kameplatos 89 

5.9.2 Repair Nameplate 89 

5.9.3 Changes to Original Pressure Relief Valve Nameplate Information ... 89 

5.9.4 Test Only Nameplate 90 

5.9.5 Replacement of Illegible or Missing Nameplates 90 

5.9.6 Requirements for Stamping and Nameplate Information 90 

5.9.6.1 Scope 90 

5.9.6.2 General Requirements for Stamping and Nameplates 91 

5.9.6.3 Additional Stamping Requirements for Repairs 91 

5.9.6.4 Additional Stamping Requirements for Alterations 

and Re-Ratings 91 

5.9.6.5 Additional Stamping Requirements for Parts 91 

5.10 Alternative Marking and Stamping for Graphite Pressure Equipment 91 

5.1 1 Stamping for Fiber Reinforced Vessels 92 

5.11.1 Removal of Original Stamping or Nameplate 92 

5.1 1 .2 Stamping for Repairs 92 

5.1 1 .3 Stamping for Alterations 93 

5.12 Stamping Requirements for Yankee Dryers 93 

5.13 Repair and Alteration Forms and Guidelines for Completing Forms 94 

5.13.1 Form R-1 Report of Repair 95 

5.13.2 Form R-2 Report of Alteration 96 

5.13.3 Form R-3 Report of Fabricated Parts 98 

5.13.4 Form R-4 Report Supplementary Sheet 100 

5.1 3.4.1 Guide for Completing National Board 

Form "R" Reports 101 

5.13.5 Form NR-1 Nuclear Components and Systems in Nuclear 

Power Plants 104 

5.13.6 Form NVR-1 Nuclear Pressure Relief Devices 106 

5.13.6.1 Guide for Completing National Board Form NR-1 

and NVR-1 Reports 107 

Section 6 Supplements 109 

Supp. 1 Steam Locomotive Firetube Boiler Repairs 1 1 

SI . 1 General Requirements 1 10 

51 .1 .1 Federal Railroad Administration (FRA) 1 1 

51 .1 .2 Requirements for Welding Activities 1 10 

Si .1.3 Materials 110 

S1 .1 .3.1 Material List for Steam Locomotive Boilers 1 1 1 

Si .1 .4 Formula and Calculations for Steam Locomotive Boilers 1 1 1 

S1 .2 Locomotive Firetube Boiler Repairs 1 12 

S1.2.1 Repair of Staybolt Holes 112 

Si .2.2 Threaded Staybolts 1 12 

51 .2.3 Ball Socket-Type Flexible Staybolts, Sleeves, and Caps 1 1 3 

51.2.4 Seal Welded Staybolts 116 

51.2.5 Welded Installation of Staybolts 116 

51. 2. 6 Diagonal Braces, Gusset Braces, and Throat 

Sheet/Tubesheet Braces 1 1 7 

SI .2.7 Threaded Studs 117 

51.2.8 Patch Bolts 117 

51 .2.9 Flues, Arch Tubes, Circulators, Thermic Siphons 1 1 7 

51 .2.9.1 Flue and Tube Re-Ending 117 

51.2.9.2 Arch Tubes 119 

51 .2.9.3 Tube Wall Thickness for Arch Tubes 1 1 9 

51 .2.9.4 Thermic Siphons 119 

5 



NATIONAL BDARD INSPECTION CODE • PART 3 — REPAIRS AND ALTERATIONS 



51.2.9.5 Circulators 119 

51.2.9.6 Re-rolling of Flute-tubes after Seal Welding 119 

SI .2.1 Repairs and Alterations to Boiler Barrel Unstayed Areas 119 

SI .2.1 1 Repairs and Alterations to Boiler Barrel Stayed Area 121 

SI. 2. 11.1 Firebox Sheet Repair 121 

SI .2. 11. 2 Firebox Patches 121 

51 .2.1 1 .3 Repair of Stayed Firebox Sheets Grooved or 

Wasted at the Mudring 122 

51. 2. 11.4 Mudring Repairs 123 

51 .2.1 1 .5 Repair of Firebox andTubesheet Knuckles 123 

51 .2.1 1 .6 Tubesheet Repairs 126 

SI .2.1 2 Seams and Joints 126 

S1 .2.12.1 Caulking Riveted Seams and Rivet Heads 126 

SI .2.12.2 Threaded Openings in Vessel Walls, Bushings, 
and Welded Nozzles (Washout Plug Holes and 

Other Connections) 127 

SI .2.13 Fittings and Cages 127 

SI .2.1 3.1 Water Gage Connection 127 

Supp. 2 Historical Boilers 128.1 

52.1 Scope 128.1 

52.2 Introduction 128.1 

52.3 Responsibilities 128.1 

52.4 Repairs and Alterations 128.1 

52.5 Construction Standards 129 

52.6 Accreditation 129 

52.7 Materials 129 

52.7.1 Material List for Historical Boilers Repairs 129 

52.7.2 Replacement Parts 130 

52.8 Welded Repair Inspection 130 

52.9 Welding 130 

52.10 Heat Treatment 130 

52.1 1 Nondestructive Examination 130 

52.12 Documentation 130 

52.13 Repair Methods 131 

52.13.1 Repair of Threaded Staybolt Holes 131 

52.13.2 Installation of Threaded Staybolts 131 

52.13.3 Seal Welding of Threaded Staybolts 132 

52.13.4 Installation of Welded Staybolts 132 

52.13.5 Threaded Studs 133 

52.13.6 Patch Bolts 134 

52.13.7 Flue andTube Re-Ending 134 

52.13.8 Flue andTube Installation 134 

52.13.9 Repairs and Alterations to Unstayed Areas 136 

52. 13.9.1 Weld Buildup of Wastage and Grooving in 

Unstayed Areas 136 

52.13.9.2 Welded Repair of Cracks in Unstayed Areas 137 

S2-.1 3.9.3 Welded Flush Patches in Unstayed Areas 137 

S2.1 3.9.4 Repair of Cracks, Grooving, and Wastage Using a 

Riveted Patch in Unstayed Areas 138 

52.13.10 Repairs and Alterations to Stayed Areas 139 

52.13.10.1 Weld Buildup of Wastage and Grooving in 

Stayed Areas 139 

52.1 3.1 0.2 Welded Repair of Cracks in Stayed Areas 1 39 

52.13.10.3 Welded Flush Patches in Stayed Areas 139 



NATIDNAL BOARD INSPECTION CODE • PART 3 — REPAIRS AND ALTERATIONS 



S2.13.10.4 Repair of Stayed Firebox Sheets Grooved or Wasted 

at the Mudring 140 

52.1 3.11 Repair of Firebox andTubesheet Knuckles 141 

52. 13. 11.1 Weld Buildup of Wastage and Grooving in Firebox 
andTubesheet Knuckles 141 

52.1 3.1 1 .2 Welded Repair of Cracks in Firebox and Tubeshecl 
Knuckles 141 

52.13.1 1.3 Welded Flush Patches in Firebox andTubesheet 
Knuckles 142 

52.13.12 Repair of Tubesheets 142 

52. 13.1 2.1 Weld Buildup of Wastage and Grooving 

in Tubesheets 142 

52.13.12.2 Welded Repair of Cracks in Tubesheets 142 

52.13.12.3 Welded Flush Patches inTubesheets 144 

52.13.13 Seams, Joints, and Rivets 145 

S2. 13. 13.1 Caulking Riveted Seams and Rivet Heads 145 

S2.13.1 3.2 Rivet Holes 145 

52.13.13.3 Assembly of Riveted Joints 145 

52.13.13.4 Riveting 145 

52.13.13.5 Seal Welding Seam, Joints, and Rivet Heads 146 

52.13.14 Repair of Openings 146 

52. 13. 14.1 Repair of Threaded Openings 146 

52.13.14.2 Repair of Handhole Openings 149 

52. 13.14.3 Repair of Fusible Plug Opening 150 

Supp. 3 Repair and Alteration of Graphite Pressure Equipment 151 

53.1 Scope 151 

53.2 Repairs 151 

53. 3 Repairs of a Routine Nature 153 

53.4 Alterations 153 

53. 5 Repair Guide for Impervious Graphite 1 53 

53. 5.1 Introduction 153 

53. 5. 2 Typical Graphite Fractures 154 

53. 5. 2.1 Major Fracture 1 54 

53. 5. 2. 2 Intermediate Fracture 154 

53. 5. 2. 3 Minor Fracture 154 

53. 5. 3 Graphite Repair by Plug Stitching 1 57 

53. 5. 3.1 Plug Stitching Procedure 157 

53. 5. 3. 2 Figures -Typical Plug Stitching Procedure 158 

53. 5. 4 Re-impregnation of Graphite Parts (Tubesheets, Heads, 

and Blocks) 158 

53. 5. 4.1 Control of Impregnation Material 1 59 

53. 5. 4. 2 Finishing the Repair 159 

Supp. 4 Repair and Alteration of Fiber-Reinforced Thermosetting Plastic 

Pressure Equipment 160 

54.1 Scope 160 

54.2 Inspector Qualifications 1 60 

54.3 Tools 160 

54.4 Limitations 161 

54.5 Repair Limitations for Filament Wound Vessels 161 

54.6 Vessels Fabricated Using Elevated Temperature Cured Resin Systems 161 

54.7 Code of Construction 161 

54.8 Materials 162 

54.9 Replacement Parts 162 

S4.10 Secondary Bonding 162 

S4.10.1 Secondary Bonding Procedure Specifications 162 



NATIONAL BOARD INSPECTION CODE • PART 3 — REPAIRS AND ALTERATIONS 



54.10.2 Performance Qualifications 162 

54.10.3 Records 162 

54.10.4 Secondary Bonder's Identification 163 

54.10.5 Secondary Bonder's Continuity 163 

54.11 Curing 163 

54.12 Nondestructive Examination 163 

54.13 Pressure and Acoustic Emission Tests 163 

S4.13.1 Pressure Cages, Measurement, and Examination 

and Test Equipment 1 63 

54.14 Acceptance Inspection 168 

54.14.1 Stamping 168 

54.14.2 Documentation 168 

54.14.3 Registration of Documentation 168 

54.14.4 Distribution of Documentation 168 

54.15 Pressure Testing For Repairs 168 

54.16 Additional Requirements for Repairs 169 

S4.1 6.1 Scope 169 

S4.1 6.2 Drawings 1 69 

$4.16.3 Repair Plan 169 

S4.16.4 Routine Repairs 169 

S4.1 6.5 Repair Methods 1 70 

S4.1 7 Additional Requirements for Alterations 1 70 

S4.1 7.1 Scope 1 70 

S4.1 7.2 Design 1 70 

54.17.3 Alteration Plan 170 

54.17.4 Calculations 170 

54.17.5 Re-Rating 1 70 

S4.1 7.6 Pressure Testing 1 71 

S4.18 Repair and Alteration Methods 1 72 

54.18.1 General Requirements 172 

54.18.2 Classification of Repairs 172 

S4.1 8.2.1 Type 1a - Repair of the Corrosion Barrier 173 

Type 1 b - Repair of the Corrosion Barrier for Vessels 

with Precision Bores 175 

Type 2 - Corrosion Barrier and Internal 

Structural Layer Repairs 177 

Type 3 - External Structural Layer Repairs 1 71 

Type 4 - Alterations 1 79 

Type 5 - Miscellaneous General External 

Repairs or Alterations 1 79 

Type 6 -Thermoplastic Repairs 1 79 

Type 7 - Gel Coat Repairs 1 79 

General Requirements for Repairs and Alterations to Yankee Dryers 181 

Scope 181 

Examinations and Test Methods 1 81 

Yankee Dryer Repair Methods 181 

S3. 3.1 Replacement Parts for Yankee Dryers 181 

Repair Guide for Yankee Dryers 181 

Procedures That Do Not Require Stamping or Nameplate Attachment 182 

Damage Repair 182 

55.6.1 Repair of Local Thinning 182 

55.6.2 Treatment of Crack-Like Flaws 183 

55.6.3 Driven Plug Repair 184 

55.6.4 Treaded Plug Repair 184 

S5.7 Alterations to Yankee Dryers 184 



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S4. 


18. 


2.3 


S4. 


18.2.4 


S4. 


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S4. 


18. 


2.6 


S4. 


18. 


2.7 


S4. 


18. 


2.8 



NATIONAL BDARD INSPECTION CODE • PART 3 — REPAIRS AND ALTERATIONS 



55.7.1 Scope 184 

55.7.2 Alteration Types 184 

Supp. 6 Repair, Alteration, and Modification of DOT Transport Tanks 185 

56.0 General Requirements 185 

56.1 Scope 185 

56.2 Construction Standards 185 

56.3 Accreditation 185 

56.4 Materials 185 

56.5 Replacement Parts 185 

56.6 Authorization 186 

56.7 Inspection 186 

S6.7.1 Inspector Duties for Repairs, Alterations, and Modifications 186 

56.8 Welding 187 

56.8.1 Welding Procedure Specification 1 87 

56.8.2 Standard Welding Procedure Specifications 1 87 

56.8.3 Performance Qualification 188 

56.8.4 Welding Records 188 

56.8.5 Welders' Identification 188 

56.8.6 Welders' Continuity 188 

56.9 Heat Treatment 188 

56.9.1 Preheating 188 

56.9.2 Postweld Heat Treatment 188 

56.9.3 Alternatives to Postweld Heat Treatment 189 

56.10 Nondestructive Examination 189 

56.1 1 Coatings and Linings 190 

56.12 Measurement, Examination, and Test Equipment 190 

56.13 Acceptance Inspection 190 

56.14 Stamping 190 

S6.14.1 Removal of Original Stamping or Nameplatc 190 

56.15 "TR" Forms 190 

56.15.1 Registration of "TR" Forms 190 

56.15.2 Form "TR" Log 190 

56.1 6 Additional Requirements for Repairs, Alterations, or Modifications 1 91 

56.16.1 Scope 191 

56.16.2 Repairs of Defects 191 

56.16.3 Modifications 191 

56.16.4 Drawings 191 

56.16.5 Authorization 191 

S6.1 7 Examination and Test 191 

56.17.1 Methods 191 

56.17.2 Stamping 192 

S6.1 7.3 Documentation 192 

56.18 Preparation ofTR Forms 192 

56.18.1 Distribution 192 

56.18.2 Registration 192 

56.1 9 Repairs, Alterations, or Modification Reports 1 92 

56.19.1 Registration of FormTR-1 and FormTR-2 193 

56.19.2 General Requirements "TR" Stamping and Nameplates 193 

56.19.3 Stamping of the "TR" Symbol 194 

Supp. 7 Requirements for Repairs to Pressure Relief Devices 1 95 

57.1 Scope 195 

57.2 General Requirements 195 

57.3 Weld Repairs to Pressure ReliefValve Parts 195 

57.4 Materials for Pressure Relief Devices 196 

57.5 Replacement Parts for Pressure Relief Devices 196 



NATIDNAL BOARD INSPECTION CODE • PART 3 — REPAIRS AND ALTERATIONS 



57.6 Initial Adjustments to Pressure ReliefValves 197 

57.7 Field Repair 197 

57.8 Audit Requirements 197 

57.9 Use of Owner-User Personnel 197 

57.1 Guide to Jurisdictions for Authorization of Owners-Users to Make 
Adjustments to Pressure ReliefValves 198 

57.10.1 General 198 

57.10.2 Training 198 

57.10.3 Documentation 198 

57.10.4 Quality System 198 

57.10.5 External Adjustments 198 

57.10.6 Repairs 199 

57.1 1 Training and Qualification of Personnel 199 

57.11.1 General 199 

57.1 1 .2 Contents of Training Program 199 

57.11.3 Qualification of Personnel 199 

57.1 1 .4 Annual Review of Qualification 199 

57.12 Welding for Pressure ReliefValves 199 

57.12.1 Welding Procedure Specifications 200 

57.1 2.2 Standard Welding Procedure Specifications 200 

57.12.3 Performance Qualification 200 

57.12.4 Welding Records 200 

57.12.5 Welders' Identification 200 

57.12.6 Welders' Continuity 200 

57.13 Heat Treatment 200 

57.13.1 Preheating 200 

57.13.2 Postweld Heat Treatment 201 

57.14 Recommended Procedures for Repairing Pressure Relief Valves 201 

57.14.1 Introduction 201 

57.14.2 Spring-Loaded Pressure ReliefValves 201 

57.14.3 Pilot Operated Safety ReliefValves 203 

Supp. 8 Recommended Guide for the Design of a Test System for Pressure 

Relief Devices in Compressible Fluid Service 206 

58.1 Introduction 206 

58.2 General 206 

58.3 Test System Description 206 

58.4 TestVessel Sizing Data 208 

58.5 Tables, Charts, and Figures 208 

Supp. 9 Procedures to Extend the "VR" Certificate of Authorization and Stamp 

to ASME "NV" Stamped Pressure Relief Devices 210 

59.1 Introduction 210 

59.2 Administrative Procedures 210 

59.3 General Rules 210 

Section 7 NBIC Policy for Metrication 213 

7.1 General ...214 

7.2 Equivalent Rationale 214 

7.3 Procedure for Conversion 214 

7.4 Referencing Tables 215 

Section 8 Preparation of Technical Inquiries to the National Board 

Inspection Code Committee 219 

8.1 Introduction 220 



i □ 



NATIONAL BOARD INSPECTION CODE • PART 3 — REPAIRS AND ALTERATIONS 



8.2 Inquiry Format 220 

8.3 Code Revisions or Additions 221 

8.4 Code Interpretations 221 

8.5 Submittals 221 

Section 9 Glossary of Terms 223 

9.1 Definitions 224 

Section 10 NBIC Approved Interpretations 227 

10.1 SCOPE 228 

10.2 Index of Interpretations 228 

10.3 Subject Index of Interpretations 232 

Section 1 1 Index 235 



1 T 



NATIDNAL BOARD INSPECTION CODE • PART 3 — REPAIRS AND ALTERATIONS 



1 z 




Part 3, Section 1 

Repairs and Alterations — General 

and Administrative Requirements 



1 3 



NATIONAL BDARD INSPECTION CODE • PART 3 



REPAIRS AND ALTERATIONS 



PART 3, SECTION 1 

REPAIRS AND ALTERATIONS — GENERAL AND 

ADMINISTRATIVE REQUIREMENTS 



1.1 



SCOPE 



a) This part provides general requirements 
that apply when performing repairs and 
alterations to pressure-retaining items. 

b) This part describes the administrative re- 
quirements for the accreditation of repair 
organizations. 1 

c) The National Board administers three 
specific accreditation programs as shown 
below: 

"R" — Repairs and Alterations to Pressure- 
Retaining Items 
"VR" — Repairs to Pressure Relief Valves 
"NR" — Repair and Replacement Activities 
for Nuclear Items 



1.2 CONSTRUCTION STANDARDS 

FOR PRESSURE-RETAINING 
ITEMS 

a) When the standard governing the original 
construction is the ASME Code or ASMF 
RTP-1, repairs and alterations to pressure- 
retaining items shall conform, insofar as 
possible, to the section and edition of the 
ASMF Code most applicable to the work 
planned. 

b) If the pressure-retaining item was not con- 
structed to a construction code or standard, 
or when the standard governing the original 
construction is not the ASME Code or ASME 
RTP-1, repairs or alterations shall conform, 
insofar as possible, to the edition of the 
construction standard or specification most 



c) 



applicable to the work. Where this is not 
possible or practicable, it is permissible to 
use other codes, standards, or specifica- 
tions, including the ASMF Code or ASME 
RTP-1 provided the "R" Certificate Holder 
has the concurrence of the Inspector and 
the Jurisdiction where the pressure-retain- 
ing item is installed. 

For historical boilers, the 1971 Edition of A07 
Section I of ASME Boiler Code, Part PR and 
PFT provides the many pressure-related 
components and features of construction 
encountered in firetube boilers. 



d) For pressure relieving devices the appli- A07 
cable standard for new valves to be used 

for reference during repairs is the ASME 
Code. ASME code cases shall be used for 
repairs when they were used in the original 
construction of the valve. ASME code cases 
may be used when they have been accepted 
for use by the NBIC committee and the 
Jurisdiction where the pressure-retaining 
item is installed. 

1 ) For pressure relieving devices the code 
case number shall be noted on the re- 
pair document and, when required by 
the code case, stamped on the repair 
nameplate. 

2) The Jurisdiction where the pressure- 
retaining item is installed shall be 
consulted for any unique requirements 
it may have established. 

e) Piping systems are designed for a variety 
of service conditions such as steam, wa- 
ter, oil, gas, or air. Design requirements 
for repairs and alterations are to meet the 



I Caution: Some jurisdictions may independently admin- 
ister a program of authorization for organizations to perforin 
repairs and alterations within that Jurisdiction. 



1 4 



NATIDNAL BOARD INSPECTION CODE • PART 3 — REPAIRS AND ALTERATIONS 



original code of construction or the code 
most appropriate for the repair or altera- 
tion. These systems shall be designed for 
the most severe conditions of pressure, 
temperature, loadings, and expected tran- 
sients considered for normal operation. All 
pipe materials, fittings, and valves shall be 
rated for the maximum service conditions 
for normal operation. Design corrosion of 
piping systems should also be considered 
when determining types of materials and 
thicknesses. 



1.3 INSPECTOR 

a) Inspection and certification shall be made 
by an Inspector holding a valid commission 
issued by the National Board and employed 
by an accredited Inservice Authorized 
Inspection Agency (see 9.0, Glossary of 
Terms, for definition of A1A). 

b) An Inspector employed by an Owner- 
User Inspection Organization or a Federal 
Inspection Agency may authorize and ac- 
cept work only on pressure-retaining items 
owned or used by the respective organ iza- 

A08 tion. Each accredited Owner-User Inspec- 
tion Organization's quality program shall 
have specific approval of the Jurisdiction 
as required. 



1.3.2 



ACCEPTANCE INSPECTION 



1.3.1 



AUTHORIZATION 



a) The Inspector making the acceptance in- 
spection shall be the same Inspector who 
authorized the repair or alteration. Where 
this is not possible or practicable, another 
Inspector may perform the acceptance in- 
spection; however, in all cases, the Inspec- 
tor who performs the acceptance inspection 
shall be an employee of the same organiza- 
tion as the Inspector who authorized the 
repair or alteration. 

b) Before signing the appropriate N'BIC Re- 
port Form, the Inspector shall review the 
drawings, ensure the repair or alteration 
was performed in accordance with the ac- 
cepted code of construction or standard, 
witness any pressure test or any acceptable 
alternative test method applied, ensure that 
the required nondestructive examinations 
have been performed satisfactorily, and 
that the other functions necessary to ensure 
compliance with the requirements of this 
Code have been satisfactorily performed. 



1.4 DEFINITIONS RELATING TO A07 

PRESSURE RELIEF DEVICES 

Unless otherwise specified in these rules and A07 
procedures, the definitions relating to pressure 
relief devices in Section 2 of ANSI/ASME PTC- 
25-2001 shall apply. 



b) 



The Inspector's authorization to perform a 1.5 
repair or alteration shall be obtained by the 
repair organization prior to initiation of a a) 
repair or alteration to a pressure-retaining 
item. The Inspector shall determine that the 
repair or alteration methods are accept- 
able. 

Subject to acceptance of the Jurisdiction, b) 
the Inspector may give approval for routine 
repairs prior to the start of work provided 
the Inspector ensures that the "R" Cer- 
tificate Holder has adequately addressed 
routine repairs in the quality program. 



ACCREDITATION 



A07 



Organizations performing repairs or al- A07 
terations to pressure-retaining items shall 
be accredited as described in this section, 
as appropriate for the scope of work to be 
performed. 

Organizations performing repairs outside A07 
the scope of the NBIC may be accredited 
and shall meet any additional requirements 
of the Jurisdiction where the work is per- 
formed. 



1 5 



NATIONAL BOARD INSPECTION CODE • PART 3 — REPAIRS AND ALTERATIONS 



1.5.1 



ACCREDITATION PROCESS 



a) The National Board administers accredita- 
tion programs for authorization of organi- 
zations performing repairs and alterations 
to pressure-retaining items and/or pressure 
relief valves. 

b) Any organization may apply to the National 
Board to obtain a Certificate of Authoriza- 
tion for the requested scope of activities. 
A review shall be conducted to evaluate 
the organization's quality system. The indi- 
vidual assigned to conduct the evaluation 
shall meet the qualification requirements 
prescribed by the National Board. Upon 
completion of the evaluation, any defi- 
ciencies within the organization's quality 
system will be documented and a recom- 
mendation will be made to the National 
Board regarding issuance of a Certificate 
of Authorization. 

c) As part of the accreditation process, an 
applicant's quality system is subject to a 
review. National Board procedures pro- 
vide for the confidential review resulting 
in recommendations to issue or not issue 
a Certificate of Authorization. 

d) When the quality system requirements of 
this Section have been met, a Certificate 
of Authorization and appropriate National 
Board symbol stamp shall be issued. 

e) The accreditation programs provide re- 
quirements for organizations performing 
repairs and alterations to pressure-retain- 
ing items. Depending upon the expected 
scope of activities at the time of review, 
organizations may be authorized to per- 
form design only, metallic or non-metallic 
repairs, and/or alterations either in the shop 
only, field only, or shop and field. Repairs 
and/or alterations to metallic and non-me- 
tallic pressure-retaining items are made 
by welding, bonding and/or mechanical 
assembly. 



1 .5.2 SCOPE ISSUANCE AND 

REVISION TO A QUALITY 
SYSTEM 

a) Any scope revision shall require authorized 
inspection agency acceptance of quality 
system changes. These changes shall be 
submitted to the National Board for accep- 
tance. A program review may be required 
by the National Board or the Jurisdiction 
to ensure quality system requirements are 
met for scope changes. Upon acceptance of 
the changes, the National Board will issue 
a Certificate of Authorization with a revised 
scope. 

b) The "VR" accreditation program provides 
requirements tor organizations performing 
repairs to pressure relief valves. For scope 
issuance and revisions, refer to 1 .7. 



1.6 



1.6.1 



ACCREDITATION OF "R" 
REPAIR ORGANIZATIONS 



SCOPE 



a) This section provides requirements that 
must be met by organizations in order to 
obtain a National Board Certificate of Au- 
thorization to use the "R" Symbol Stamp for 
the repair or alteration of pressure-retaining 
items. Organizations may be authorized to 
perform repairs only, or repairs and altera- 
tions. 

b) The issuance of the "R" Stamp is not re- 
stricted to organizations whose primary 
business is to repair and alter pressure- 
retaining items, nor to manufacturers of 
pressure-retaining items. Owners and Us- 
ers of pressure-retaining items and other 
organizations that qualify in accordance 
with these rules may also obtain the "R" 
Stamp. 



1 6 



NATIONAL BOARD INSPECTION CODE • PART 3 



REPAIRS AND ALTERATIONS 



Owners or users may be accredited for 
both a repair and inspection program pro- 
vided the owner or user complies with [he 
requirements of the "R" program and the 
National Board requirements of NB 371 
for an Owner-User Inspection Organiza- 
tion. The requirements of 1.6.2(a) do not 
apply if the owner or user chooses to use 
the Owner-User Inspection Organization 
to accept the repair quality system when: 

1 ) There is no conflict with jurisdictional 
requirements. 

2) The line of authority for the Owner-User 
Inspection Organization shall be inde- 
pendent of the organization responsible 
for execution of "R" program work. 

3) The process and Inspector limitations 
are described in the written Owner- 
User Inspection Organization's quality 
system manual. 



1.6.2 PREREQUISITES FOR ISSUING A 

NATIONAL BOARD CERTIFICATE 
OF AUTHORIZATION 

Before an organization can obtain a National 
Board "R" Certificate of Authorization, the or- 
ganization shall: 

a) Have and maintain an Inspection Agree- 
ment with an Authorized Inspection 
Agency; 

b) Have, in the English language, a written 
Quality System that complies with the re- 
quirements of this section and includes the 
expected scope of activities; 

A07 c) Have the current edition and addendum 
A08 of the National Board Inspection Code, all 
parts; and 

d) Have available a copy of the code of con- 
struction appropriate to the intended scope 
of work. 



1 .6.3 PROCEDURE FOR OBTAINING 

OR RENEWING A NATIONAL 
BOARD CERTIFICATE OF 
AUTHORIZATION 

a) Prior to issuance or renewal of a National 
Board "R" Certificate of Authorization, the 
organization and its facilities are subject to 
a review of its Quality System. The imple- 
mentation of the Quality System shall be 
satisfactorily demonstrated by the; organi- 
zation. The National Board reserves the 
absolute right to cancel, refuse to issue, or 
renew such authorization. 

b) Organizations desiring to renew or obtain A07 
a National Board Certificate of Authoriza- 
tion shall apply to the National Board using 
forms obtained from the National Board. 
Application for renewal shall be made prior 

to the expiration date of the Certificate of 
Authorization. 

c) When an organization has plants or shops 
in more than one location, the organiza- 
tion shall submit separate applications for 
each plant or shop. The organization may 
perform repairs or alterations in its plants, 
shops, or in the field, provided such opera- 
tions are described in the organization's 
Quality System. 

d) Upon notification of the review dates from 
the National Board, it is the responsibility 
of the organization to make arrangements 
for the review. 

e) The Review Team, as a minimum, shall 
consist of one representative each from 
the Authorized Inspection Agency and the 
Jurisdiction. 2 



2 Jurisdiction: The National Board member jurisdiction 
where the organization is located. Alternatively, where the Ju- 
risdiction elects not to perform the review or where there is 
no Jurisdiction or where the Jurisdiction is the organization's 
Authorized Inspection Agency, the National Board of Boiler 
and Pressure Vessel Inspectors will represent the Jurisdiction. 
At the Jurisdiction's discretion, the Jurisdiction may choose to 
be a member of the review team if the Jurisdiction chooses not 
to be the team leader. 



1 V 



NATIONAL BOARD INSPECTION CODE • PART 3 — REPAIRS AND ALTERATIONS 



f) The Review Team shall conduct an evalu- 
ation of the organization's Quality System. 
The organization shall demonstrate suffi- 
cient implementation of the Quality System 
to provide evidence of the organization's 
knowledge of welding, nondestructive 
examination, postweld heat treatment, 
and other repair or alteration activities 
performed appropriate for the requested 
scope of work. The demonstration may 
be performed using current work, a dem- 
onstration mock-up, or a combination of 
both. 

g) A recommendation to issue, renew, or 
withhold the National Board Certificate 
of Authorization shall be included in a 
Review Report prepared by the Review 
Team. The completed Review Report shall 
be forwarded to the National Board. 

h) If proper administrative fees are paid and 
all other requirements are met, a Certificate 
of Authorization will be issued evidencing 
permission to use the "R" Symbol Stamp. 
The certificate shall expire on the triennial 
anniversary date. 

i) When an organization holding a National 
Board Certificate of Authorization changes 
ownership, name, location, or address, 
the National Board shall be notified. The 
Certificate of Authorization may be revised 
by submitting an application for National 
Board "R" Certificate of Authorization; 
however, a re- review may be required. 

j) The holder of an ASME Code Symbol 
Stamp, whose facilities were reviewed (with 
the exception of "V," "UV," "HV," "NV," 
and "H" [cast iron]) may obtain National 
Board authorization without a review of its 
facilities, provided: 

1 ) The organization has a Quality System 
to cover the scope of the repairs or al- 
terations to be made, subject to review 
by the Jurisdiction; and 

2) The application for the "R" Certificate 
of Authorization is submitted within 



12 months from the issuance of the 
ASME Certificate of Authorization. The 
initial Certificate of Authorization shall 
be issued to expire concurrent with 
the ASME Certificate of Authorization. 
Subsequent certificates shall be re- 
newed upon a successful review and 
implementation of its Quality System 
by a National Board Representative. 

k) The Jurisdiction may audit the Quality 
System and activities of an organization 
upon a valid request from an owner, user, 
inspection agency, or the National Board. 

I) The NBIC Committee may at any time 
change the rules for the issuance of Certifi- 
cates of Authorization and use of the "R" 
Symbol Stamp. These rules shall become 
binding on all certificate holders. 



1 .6.4 NATIONAL BOARD "R" 

SYMBOL STAMP 

a) All "R" Symbol Stamps shall be obtained 
from the National Board of Boiler and Pres- 
sure Vessel Inspectors. Authorization to use 
the "R" Symbol Stamp may be granted by the 
National Board at its absolute discretion. 

b) The "R" Symbol Stamp is furnished on loan 
by the National Board for a nominal fee. 
Each organization shall agree if authoriza- 
tion to use the "R" Symbol Stamp is granted, 
that the "R" Symbol Stamp is at all times 
the property of the National Board and will 
be promptly returned upon demand. If the 
organization discontinues the use of the 
"R" Symbol Stamp, inspection agreement 
with an Authorized Inspection Agency, or if 
the Certificate of Authorization has expired 
and no new certificate has been issued, the 
"R" Symbol Stamp shall be returned to the 
National Board. 

c) The organization's Quality System shall 
provide for adequate control of the "R" 
Symbol Stamp. Provisions may be made 
for the issuance of the "R" Symbol Stamp 
for use at various field locations. 



i B 



NATIDNAL BOARD INSPECTION CODE • PART 3 



REPAIRS AND ALTERATIONS 



Code Report Form 1 upon completion of the 
work. 



or altered component can be considered in 
compliance with the NBIC. 



o) Inspections 

The manual shall make provisions for the 
Inspector to have access lo all drawings, 
design calculations, specifications, proce- 
dures, process sheets, repair or alteration 
procedures, test results, and other docu- 
ments as necessary to ensure compliance 
with the NBIC. A copy of the current man- 
ual shall be available to the inspector. 

p) Report of Repair or Alteration Form 

The manual shall indicate the title of the 
individuals responsible for preparing, 
signing, and presenting the NBIC Report 
Forms to the Inspector. The distribution of 
the NBIC Report Forms 3 shall be described 
in the manual. 

q) Exhibits 

Any forms referenced in the manual shall 
be included. The form may be a part of 
the referencing document or included as 
an appendix. For clarity, the forms may be 
completed and identified as examples. The 
name and accepted abbreviations of the 
"R" Certificate Holder shall be included in 
the manual. 

r) Construction Code 

The manual shall include provisions for 
addressing the requirements that pertain 
to the specific construction code for the 
equipment being repaired or altered. 

s) Nonconforming Items 

There shall be a system acceptable to 
the Inspector for the correction of non- 
conformities. A nonconformance is any 
condition that does not comply with the 
applicable rules of the NBIC, construction 
code, jurisdictional requirements, or the 
quality system. Nonconformance must be 
corrected or eliminated before the repaired 



1.7 



1.7.1 



ACCREDITATION OF "VR" 
REPAIR ORGANIZATIONS 



SCOPE 



3 NLSIC Report Form: National Board Form R-l for Repairs, 
Form R-2 for Alterations, or Form R-3 for Fabricated Parts. 



a) These administrative rules and procedures 
are provided for those who wish to obtain 
a National Board Certificate of Authoriza- 
tion for use of the "VR" (Repair of Pressure 
Relief Valves) symbol stamp. It should be 
noted that the issuance of the "VR" stamp 
is not restricted to companies whose pri- 
mary business is the repair of pressure relief 
valves, nor to manufacturers or assemblers 
that hold an ASME "V," "HV," "UV," or "NV" 
Code symbol stamp. Owners and users of 
boilers and pressure vessels and other or- 
ganizations that qualify in accordance with 
the National Board Rules and Regulations 
may also obtain the "VR" Certificate and 
stamp. 

b) In order to provide due process in the is- 
suance, renewal, and revocation of "VR" 
symbol stamps and certificates of authori- 
zation, the National Board Appeals Com- 
mittee procedures provide an affected "VR" 
Certificate of Authorization applicant the 
right of appeal, or to provide additional 
information that may affect the Committee's 
decision. 



1.7.2 JURISDICTIONAL 

PARTICIPATION 

The National Board member jurisdiction in 
which the "VR" organization is located is 
encouraged to participate in the review and 
demonstration of the applicant's quality system. 
The Jurisdiction may require participation in 
the review of the repair organization and the 
demonstration and acceptance of the repair 
organization's quality system manual. 



2 1 



NATIONAL BOARD INSPECTION CODE • PART 3 



REPAIRS AND ALTERATIONS 



1.7.3 



GENERAL RULES 



1.7.5.2 



ISSUANCE OF CERTIFICATE 



The general rules of the National Board "VR" 
certification program apply only to the repair 
of National Board capacity certified ASME 
Code Section I "V" stamped, Section IV "HV" 
marked, and Section VIII "UV" stamped pres- 
sure relief valves that: 

a) Have been in service or have been exposed 
to environmental or other conditions such 
that there is reason to question their ability 
to perform equivalent to the standards for 
new valves; or 

b) Any or all of the valve's external adjustment 
seals have been broken, opened, or other- 
wise disturbed, regardless of the valve's age 
or service status. 



1.7.4 



REPAIR OF NUCLEAR VALVES 



Provided that the requirements of Supplement 9 
and applicable requirements of these rules are 
met, the "VR" certificate may be extended to 
apply to the repair of any ASME Code Section 
III, Class 1 , 2, or 3, pressure relief devices that 
have been capacity certified by the National 
Board and have been in service, regardless of 
their intended function, in a nuclear system. 



1.7.5 



1.7.5.1 



ISSUANCE AND RENEWAL OF 
THE "VR" CERTIFICATE OF 
AUTHORIZATION 



GENERAL 



a) Repair organizations, manufacturers, as- 
semblers, or users that make repairs to the 
American Society of Mechanical Engineers 
(ASME) Code symbol, stamped or marked 
(as applicable), and The National Board 
of Boiler and Pressure Vessel Inspectors 
(National Board) capacity certified pres- 
sure relief valves may apply to the National 
Board for a Certificate of Authorization to 
use the "VR" symbol. The National Board 
may at any time, through the NBIC Com- 
mittee, modify the regulations concerning 
the issuance and use of such valve repair 
symbol. All such modified regulations shall 
become binding upon holders of valid 
Valve Repair Certificates of Authorization. 

b) Authorization to use the "VR" stamp may be 
granted or withheld by the National Board 
in its absolute discretion. If authorization is 
granted and proper administrative fees paid, 
a Certificate of Authorization will be issued 
evidencing permission to use such a sym- 
bol, expiring on the triennial anniversary 
date. The certificate will be signed by the 
National Board Chairman of the National 
Board of Trustees, the Executive Director, 
or any other duly authorized officer. 

c) The certificate shall list the physical, per- 
manent address of record for the certificate 
holder's shop/plant. For field-only scopes, 
this address of record shown on the Certifi- 
cate of Authorization is where administra- 
tive, technical, and quality aspects of the 
business are controlled. 



Authorization to use the stamp bearing the of- 
ficial National Board "VR" symbol as shown 
in Section 5 of this Part, will be granted by the 
National Board pursuant to the provisions of the 
following administrative rules and procedures. 
Supplement 9 of this Part, provides rules for 
the repair of ASME Section III "NV" stamped 
pressure relief devices. 



1.7.5.3 



RENEWAL OF CERTIFICATE 



The Certificate of Authorization is renewable 
every three (3) years subject to a review of 
the Quality System by a representative of 
the National Board, review and acceptance 
of the representative's report by the National 
Board, and successful completion of capacity 



22 



NATIONAL BOARD INSPECTION CODE • PART 3 



REPAIRS AND ALTERATIONS 



verification tests. See 1 .7.8 for exceptions. The 
applicant should apply to the National Board 
for renewal of authorization and re-issuance 
of the certificate prior to the date of expira- 
tion. The National Board reserves the absolute 
right to cancel, refuse to issue, or renew such 
authorization. 



1 .7.5.4 REVIEW OF APPLICANT'S 
FACILITY 

a) Before issuance or renewal of pressure relief 
"VR" Certificates of Authorization, the re- 
pair organization, its written quality system, 
and its facilities are subject to a review and 
verification of implementation of its quality 
system by a representative of the National 
Board. The implementation demonstration 
shall include, as a minimum, disassembly, 
inspection, repair, application of special 
processes, reassembly setting, and testing 
of valves within the scope of the applicant's 
quality system. 

b) The applicant shall repair and submit for 
verification testing one (1) valve for each 
Code section (except Section III) and test 
fluid (steam, air/gas, liquid) which will ap- 
pear on the Certificate of Authorization. A 
minimum of two (2) valves arc required 
regardless of Code sections or test fluid. 
The valves shall be within the capabilities 
of the National Board accepted laboratory. 
When an applicant is using the provisions 
of 4.5.2, the applicant shall submit one 
additional Section VIII steam valve set on 
air for verification testing on steam. 

c) The applicant shall have a copy of the Na- 
tional Board Pressure Relief Device Certi- 
fications publication, NB-18, dated within 
one year (available from the National 
Board Web page), the latest edition and 
addenda of the National Board Inspection 

A08 Code (NBIC), all parts; and the ASME Code 
section(s) that the organization is including 
in its scope. 



d) It is the responsibility of the valve repair 
organization to make arrangements for 
this review. Certificates cannot be issued 
or renewed until the National Board is in 
receipt of approval of this review. Wherever 
possible, National Board reviews of valve 
repair organizations shall be coordinated 
with ASME reviews, when applicable. 

c) For field-only repair scopes, the review shall 
encompass both the applicant's address of 
record and field repair demonstration site. 
The demonstration site shall be represen- 
tative of that typically encountered by the 
applicant (see 1 .7.5.6). 



1.7.5.5 



VERIFICATION TESTING 



a) Before the "VR" Certificate of Authorization 
and stamps may be issued or renewed, the 
demonstration valves must successfully 
complete capacity and operational verifi- 
cation tests at a National Board accepted 
testing laboratory. See 1.7.5.6 and 1.7.8 
for exceptions. The valves shall be typical 
of those repaired by the organization and 
within the capabilities of the testing labora- 
tory. 

b) Tests conducted at the accepted testing 
laboratory shall be witnessed by a represen- 
tative of the National Board. The purpose of 
the tests is to ensure that the repairs have 
been satisfactorily carried out and the func- 
tion and operation of the valves meet the 
requirements of the section of the ASME 
Code to which they were manufactured. 

c) Valves not meeting the function or opera- 
tional requirements of the section of the 
ASME Code to which they were manufac- 
tured shall be considered to have failed. 
Replacement valves shall be repaired and 
selected for testing as stated above, at a 
rate of two (2) valves for each one (1 ) that 
failed. 



23 



NATIONAL BDARD INSPECTION CODE • PART 3 — REPAIRS AND ALTERATIONS 



If either or both of these replacement 
valves fail to meet the above criteria, 
the applicant shall document the 
cause of the noted deficiencies and 
actions taken to guard against future 
occurrence. Upon acceptance of this 
information by the National Board, one 
(1) additional valve for each replace- 
ment valve that failed shall be repaired 
and tested. The valve(s) shall be of the 
same ASME Code Section, fluid and set 
pressure scope, as the valve previously 
failing to meet the test requirement. 

Failure of this valve(s) to meet the ASME 
Code to which the valve was manufac- 
tured shall be cause for consideration 
by the National Board of revocation of 
the "VR" Certificate of Authorization 
or acceptance of alternative corrective 
action. 



1.7.5.6 VERIFICATION TESTING 

ALTERNATIVES 

a) In such cases where all valves repaired by 
the applicant for a specified ASME Code 
Section or test fluid exceed the capabilities 
of the accepted testing laboratory, valves for 
that ASME Code Section or test fluid shall 
be selected as specified in 1.7.5.4, and a 
demonstration test shall be successfully 
performed in lieu of verification testing 
specified in 1 .7.5.5 above. The demonstra- 
tion tests shall be conducted at a facility 
mutually agreeable to the National Board 
representative, the facility owner, and the 
applicant. The purpose of these tests is to 
demonstrate, in the presence of a National 
Board representative, that the repaired 
valves shall have adequate seat tightness 
at the maximum expected operating pres- 
sure prior to lifting, shall open within the 
required set pressure tolerance, operate 
consistently without chatter, and reclose 
within the required blovvdown. 



b) If a valve lift-assist device is used by the 
applicant to establish set pressure after re- 
pairs, this device must also be used to set 
the demonstration valves. 

c) If either of these valves fail to meet the 
above criteria, then replacement valves 
shall be repaired and tested at a rate of two 
valves for each one that failed. 

1) If either or both of these replacement 
valves fail to meet the above criteria, 
the applicant shall document the 
cause of the noted deficiencies and 
actions taken to guard against future 
occurrence. Upon acceptance of this 
information by the National Board, one 
(1) additional valve for each replace- 
ment valve that failed shall be repaired 
and tested. The valve(s) shall be of the 
same ASMb Code section, fluid, and set 
pressure scope as the valve previously 
failing to meet the test requirement. 

2) Fai lure of this valve(s) to meet the ASME 
Code to which the valve was manufac- 
tured shall be cause for consideration 
by the National Board of revocation of 
the "VR" Certificate of Authorization 
or acceptance of alternative corrective 
action. 



1.7.6 USE OF THE "VR" 

AUTHORIZATION 



1.7.6.1 TECHNICAL REQUIREMENTS 

The administrative requirements of 1 .7 for use 
of the "VR" stamp shall be used in conjunction 
with the technical requirements for valve repair 
as described in Supplement 7 of the NBIC. 
Those requirements shall be mandatory when 
a "VR" repair is performed. 



24 



NATIONAL BOARD INSPECTION CODE • PART 3 



REPAIRS AND ALTERATIONS 



tion Agency in accordance with NB-360," 
NB-369, 4 and ASME Section XI; 

b) Have in the English language a written 
Quality System Program that complies 
with the requirements of this Section and 
addresses controls for the intended scope 
of activities; 

A08 c) Have a current edition and addenda of the 
NBIC, all parts; and 

d) Have available copies of the original code 
of construction appropriate to the intended 
scope of work and the applicable edition 
and addenda of ASME Section XI, as re- 
quired by the regulatory authority. 6 



1 .8.3 PROCEDURES FOR OBTAINING 

OR RENEWING A NATIONAL 
BOARD "NR" CERTIFICATE OF 
AUTHORIZATION 

a) Prior to issuance or renewal of a National 
Board "N R" Certificate of Authorization, the 
organization and its facilities are subject to 
a review of its Quality System Program. The 
implementation of the Quality System Pro- 
gram shall be satisfactorily demonstrated by 
the organization. Demonstration of imple- 
mentation shall meet the most stringent 
code requirements for the scope of work 
to be performed by the organization. The 
National Board reserves the absolute right 
to cancel, refuse to issue, or renew such 
authorization. The National Board will 
return fees paid for the unexpired term of 
the certificate. 

b) Organizations desiring to obtain a National 
Board Certificate of Authorization shall 



4 KB-360, Criteria for Acceptance of Authorized Inspection 
Agencies for New Construction. 

5 NB-369, Qualification and Duties for Authorized Inspec- 
tion Agencies (AlAs) Performing /nserv/ce Inspection Activities 
and Qualification of Inspectors of Boilers and Pressure Vessels. 
f> Regulatory Authority. A federal government agency, such 
as the United States Nuclear Regulatory Commission, empow- 
ered to issue and enforce regulations concerning the design, 
construction, and operation of nuclear power plants. 



apply to the National Board using forms 
obtained from the National Board. Ap- 
plication for renewal shall be made prior 
to the expiration date of the Certificate of 
Authorization. 

c) These procedures also apply to qualified 
organizations that make repairs to ASME 
Section III "NV" pressure relief devices. 
An organization that holds a valid "NR" 
Certificate of Authorization shall, for the 
purpose of these procedures, be known as 
an authorized nuclear repair organization. 

d) Authorized Nuclear Inspection Agencies 
and Inspectors referred to in these proce- 
dures shall meet the requirements of and 
have been qualified and commissioned in 
accordance with the National Board Rules 
for Commissioned Inspectors. 

e) Repair/replacement activities performed 
under the "NR" Certificate of Authorization 
must be in accordance with the provisions 
of the NBIC, Section XI of the ASME Code 
and the rules of the Jurisdiction. 

f) Each authorized nuclear repair organization 
shall maintain a documented Quality Sys- 
tem Program that meets the requirements 
of 1.8.5.1. The Quality System Program 
shall be commensurate with the scope of 
the organization's activities and shall be 
acceptable to the jurisdiction, the Autho- 
rized Nuclear Inspection Agency, and the 
National Board. 

g) Before an " N R" Certificate of Authorization 
will be issued or renewed, the applicant 
must have the Quality System Program 
and the implementation of the program 
reviewed and found acceptable by repre- 
sentatives of the National Board, the Juris- 
diction, and the accredited Authorized 
Nuclear Inspection Agency. If the applicant 
is an ASME "N"-type Certificate of Authori- 
zation holder, has demonstrated within the 
last 12 months the implementation of the 
quality program, and can verify by docu- 
mentation that the organization is capable 
of implementing its quality program as 



3 i 



NATIDNAL BOARD INSPECTION CODE • PART 3 — REPAIRS AND ALTERATIONS 



being in compliance with this part, a further 
verification implementation by the survey 
team may not be necessary. 

h) Applicants that do not hold valid ASME 
"N"-type Certificates of Authorization shall 
demonstrate, by documentation and actual 
implementation, that they are capable of 
performing repair/replacement activities in 
accordance with the requirements of Sec- 
tion XI and the scope of their application 
for an "NR" Certificate of Authorization. 

i) For National Board authorization to repair 
ASME "NV7"NB"-stamped pressure relief 
devices, the applicant shall hold a valid 
"VR" Certificate of Authorization for the 
repair of ASME Section III pressure relief 
valves and also meet the applicable require- 
ments for "NR" certification and Supple- 
ment 8. 

j) When these requirements have been met, 
the applicant may be issued an "NR" 
Certificate of Authorization, which clearly 
outlines the scope of work for Section III 
pressure relief devices. 

k) The Jurisdiction will be the National 
Board member Jurisdiction in which the 
applicant is located. If the implementa- 
tion of the Quality System Program takes 
place outside of the Jurisdiction where the 
applicant's program was reviewed, the 
National Board member in the Jurisdiction 
where the implementation takes place may 
participate in this portion of the survey. At 
the request of the Jurisdiction, the National 
Board representative may also act for said 
Jurisdiction. 

I) Where there is no National Board member 
Jurisdiction, the applicant's Quality System 
Program shall be acceptable to representa- 
tives of the National Board and the Autho- 
rized Nuclear Inspection Agency. 



m) The applicant shall request the National 
Board to evaluate the Quality System Pro- 
gram and implementation prior to the issu- 
ance of an "NR" Certificate of Authoriza- 
tion. The National Board, when requested 
through the appropriate form, will arrange 
for an evaluation of the applicant's Quality 
System Program. The program will be evalu- 
ated on the basis of its compliance with the 
National Board rules for certification. The 
program shall be adequate to control the in- 
tended scope of work. The "NR" Certificate 
of Authorization that is issued shall specify 
the scope and limits of work for which the 
applicant is certified. 

n) Revisions to the Quality System Program 
shall be acceptable to the Authorized 
Nuclear Inspector Supervisor of the Au- 
thorized Nuclear Inspection Agency before 
implementation. 

o) The "NR" Certificate of Authorization holder 
shall be subject to an audit annually by the 
Authorized Nuclear Inspection Agency to 
assure compliance with the Quality System 
Program. 

p) Upon notification of the survey dates from 
the National Board, it is the responsibility 
of the organization to make arrangements 
for the survey. 

q) The Survey Team, as a minimum, shall 
consist of one representative each from 
the National Board, Authorized Nuclear 
Inspection Agency, and Jurisdiction. 

r) A recommendation to issue, renew, or with- 
hold the National Board Certificate of Au- 
thorization for the "NR" Symbol Stamp shall 
be included in a summary report prepared 
by the survey team leader. The completed 
summary report shall be forwarded to the 
National Board. 

s) If proper administrative fees are paid and 
all other requirements are met, an "NR" 
Certificate of Authorization will be issued 



32 



NATIONAL BOARD INSPECTION CODE • PART 3 — REPAIRS AND ALTERATIONS 



Certificate Holder to ensure that all 
personnel performing quality func- 
tions within the scope of these rules, 
including personnel of subcontracted 
services, are qualified as specified in 
these rules. The assignment of qualified 
personnel shall be at the discretion of 
the "NR" certificate holder. 

4) The "NR" Certificate Holder shall be 
responsible for advising his Authorized 
Nuclear Inspection Agency of any pro- 
posed changes to the Quality System 
Manual and shall have acceptance 
of the Authorized Nuclear Inspection 
Agency's Authorized Nuclear Inspector 
Supervisor before putting such changes 
into effect. The "NR" Certificate Holder 
shall make a current copy of the Qual- 
ity System Manual available to the Au- 
thorized Nuclear Inspector. The "NR" 
Certificate Holder shall be responsible 
for promptly notifying the Authorized 
Nuclear Inspector of such accepted 
changes, including evidence of ac- 
ceptance by the Authorized Nuclear 
Inspection Agency. 

5) The quality of all repair/replacement ac- 
tivities shall be controlled at all points 
necessary to ensure conformance with 
the requirements of these rules and 
the "NR" Certificate Holder's Quality 
System Manual. 

6) The Certificate Holder shall make avail- 
able to the Authorized Nuclear Inspec- 
tor such drawings and process sheets 
as are necessary to make the Quality 
System Program intelligible. 

Design Control 

1) ASME Section XI establishes that the 
owner is responsible for design in con- 
nection with repair/replacement activi- 
ties. The "NR" Certificate Holder must 
ensure that the design specification, 
drawings, or other specifications or in- 



structions furnished by the owner satisfy 
the code edition and addenda of the 
owner's design specification. To satisfy 
this requirement, the "NR" Certificate 
Holder shall establish requirements 
that correctly incorporate the owner's 
design specification requirements into 
their specifications, drawings, proce- 
dures, and instructions, which may be 
necessary to carry out the work. The 
"NR" Certificate Holder's system shall 
include provisions to ensure that the 
appropriate quality standards are speci- 
fied and included in all quality records. 
These records shall be reviewed for 
compliance with the owner's design 
specification and the requirements of 
Section XI of the ASMF Boiler and Pres- 
sure Vessel Code. 

2) If the "NR" Certificate Holder's speci- 
fications, drawings, procedures, and 
instructions conflict with the owner's 
design specification, a system must be 
implemented that will resolve or elimi- 
nate the deficiency. This system must 
be reconciled with the owner and the 
"NR" Certificate Holder in accordance 
with IWA-4000 of Section XI of the 
ASME Code. 

d) Procurement Document Control 

Documents for procurement of materials, 
items, and subcontracted services shall in- 
clude requirements to the extent necessary 
to ensure their compliance with the owner's 
design specifications and IWA-4000 of 
Section XI of the ASME Code. To the extent 
necessary, procurement documents shall 
require suppliers to maintain a Quality Sys- 
tem Program consistent with the applicable 
requirements of the edition and addenda 
of the code of construction to which the 
items are constructed. Measures shall be 
established to ensure that all purchased 
material, items, and services conform to 
these requirements. 



35 



NATIONAL BOARD INSPECTION CODE • PART 3 



REPAIRS AND ALTERATIONS 



e) Instructions, Procedures and Drawings 
Activities affecting quality shall be pre- 
scribed by documented instructions, 
procedures or drawings of a type appro- 
priate to the circumstances and shall be 
accomplished in accordance with these 
instructions, procedures, or drawings. In- 
structions, procedures, or drawings shall 
include appropriate quantitative and quali- 
tative criteria for determining that activities 
affecting quality have been satisfactorily 
accomplished. The "NR" Certificate Holder 
shall maintain a written description of 
procedures, instructions, or drawings used 
by his organization for control of quality 
and examination requirements detailing 
the implementation of the Quality System 
requirements. Copies of these procedures 
shall be readily available to the Authorized 
Nuclear Inspector. 

f) Document Control 

The program shall include measures to 
control the issuance, use, and disposi- 
tion of documents, such as specifications, 
instructions, procedures, and drawings, 
including changes thereto. These measures 
shall ensure that the latest applicable docu- 
ments, including changes, are reviewed 
for adequacy and approved for release by 
authorized personnel and distributed for 
use at the location where the prescribed 
activity is performed. 

g) Control of Purchased Material, Items, and 
Services 

Measures shall be established to ensure that 
all purchased material, items, and services 
conform to the requirements of the owner's 
design specifications and applicable edition 
and addenda of the code of construction 
and Section XI of the ASME Code. These 
measures shall include identification for 
material traceability. Provisions shall be 
identified for source evaluation and objec- 
tive evidence shall be provided evidencing 
quality standards for material examination 
upon receipt. 

h) Identification and Control of Material and 
Items 



1 ) Measures shall be established for identifi- 
cation and control of material and items, 
including partially fabricated assemblies. 
These measures shall ensure that iden- 
tification is maintained and traceable, 
either on the material or component, or 
on records throughout the repair/replace- 
ment activity. These measures shall be 
designed to prevent the use of incorrect 
or defective items and those which have 
not received the required examinations, 
tests, or inspections. 

2) Permanent or temporary unit identi- 
fication marks shall be applied using 
methods and materials that are legible 
and not detrimental to the component 
or system involved. Such identification 
shall be located in areas that will not 
interfere with the function or quality 
aspects of the item. 

3) Certified Material Test Reports, shall be 
identified as required by the applicable 
material specification in Section II of 
the ASME Code and shall satisfy any 
additional requirements specified in the 
original code of construction. The Certi- 
fied Material Test Report or Certificate 
of Compliance need not be duplicated 

for submission with compliance docu- A08 
ments when a record of compliance 
and satisfactory reviews of the Certified 
Material Test Report and Certificates of 
Compliance is provided. Documents 
shall provide a record that the Certified 
Material Test Report and Certificates 
of Compliance have been received, 
reviewed, and found acceptable. When 
the "NR" Certificate Holder Scope 
authorizes the organization to perform 
examinations and tests in accordance 
with the original code of construction, 
the "NR" Certificate Holder shall cer- 
tify compliance either on a Certified 
Material Test Report or Certificate of 
Conformance that the material satis- 
fies the original code of construction 
requirements. 



36 



NATIONAL BOARD INSPECTION CODE • PART 3 



REPAIRS AND ALTERATIONS 



tern Program, except those required by 
the owner or listed in 1 .8.5.1 (m)(2)(a) 
thru (g) above, shall be maintained at 
a place mutually agreed upon by the 
owner and the "NR" Certificate Holder. 
These records shall be maintained for 
a period of five years after completion 
of the repair/replacement activity. 

4) The original of the completed Form NR- 
1 or Form NVR-1, as applicable, shall 
be registered with the National Board 
and, if required, a copy forwarded 
to the Jurisdiction where the nuclear 
power plant is located. 

n) Examination or Test Status 

Measures shall be established to indicate 
examination and test status of parts, items, 
or components during the repair/replace- 
ment activity. The system used shal I provide 
positive identification of the part, item, or 
component by means of stamps, labels, 
routing cards, or other acceptable methods. 
The system shall include any procedures or 
instructions to achieve compliance. Also, 
measures shall be provided for the identi- 
fication of acceptable and unacceptable 
items. They shall also include procedures 
for control of status indicators, including 
the authority for application and removal 
of status indicators. 

o) Nonconforming Materials or Items 

Measures shall be established to control 
materials or items that do not conform 
to requirements in order to prevent their 
inadvertent use, including measures to 
identify and control the proper installation 
of items and to preclude nonconformance 
with the requirements of these rules. These 
measures shall include procedures for 
identification, documentation, segregation, 
and disposition. Nonconforming items shall 
be reviewed for acceptance, rejection, or 
repair in accordance with documented pro- 
cedures. The responsibility and authority 
for the disposition of nonconforming items 
shall be defined. Repaired or modified items 
shall be re-examined in accordance with 



the applicable procedures. Measures that 
control further processing of a nonconform- 
ing or defective item, pending a decision 
on its disposition, shall be established and 
maintained. Ultimate disposition of non- 
conforming items shall be documented. 

p) Corrective Action 

1) Measures shall be established to ensure 
that conditions adverse to quality such 
as failures, malfunctions, deficien- 
cies, deviations, defective material 
and equipment, and other nonconfor- 
mances are promptly identified and 
corrected. 

2) In the case of significant conditions 
adverse to quality, the measures shall 
also ensure that the cause of these con- 
ditions be determined and corrected to 
preclude repetition. The identification 
of significant conditions adverse to 
quality, the cause, and condition and 
the corrective action taken shall be 
documented and reported to the ap- 
propriate levels of management. 

3) The requirements shall also extend to 
the performance of subcontractors' cor- 
rective action measures. 

q) Audits 

A comprehensive system of planned and 
periodic audits shall be carried out by the 
"NR" Certificate Holder's organization to 
ensure compliance with the Quality System 
Program and to determine its effectiveness. 
Audits shall be performed in accordance 
with written procedures or checklists by 
personnel not having direct responsibilities 
in the areas being audited. Audit results 
shall be documented by the auditing per- 
sonnel for review by management having 
responsibility in that area. Follow-up action, 
including re-audit of deficient areas, shall 
be taken where indicated. Audit results 
shall be made available to the Authorized 
Nuclear Inspector. 



39 



NATIONAL BOARD INSPECTION CODE ■ PART 3 



REPAIRS AND ALTERATIONS 



Authorized Nuclear Inspector 
Measures shall be taken to reference the 
commissioned National Board Authorized 
Nuclear Inspector, qualified in accordance 
with the National Board Rules for Commis- 
sioned Inspectors, to ensure that the latest 
documents including the Quality System 
Program will be made available to the in- 
spector. The Authorized Nuclear Inspector 
shall be consulted prior to the issuance of 
a repair/replacement program in order that 
the Inspector may select any inspection or 
hold points in the program. The Authorized 
Nuclear Inspector shall not sign Form NR- 
1 or Form NVR-1, as applicable, unless 
satisfied that all work carried out is in ac- 
cordance with the NBIC, ASME Section XI, 
and any jurisdictional requirements. 

Exhibits 

Forms referenced in the Quality System 
Manual shall be explained in the text and 
included as part of the referencing docu- 
ment or as an appendix. Forms shall be 
controlled and identified to show the latest 
approved revision, exhibit name, and other 
corresponding references as stated in the 
Quality System manual. 



1.8.6 INTERFACE WITH THE OWNER'S 

REPAIR/REPLACEMENT 
PROGRAM 

A07 Interface with the owner's repair/replacement 
program shall meet the following: 

a) The repair/replacement plan shall be sub- 
ject to the acceptance of the jurisdiction 
and the owner's Authorized Nuclear In- 
service Inspector (ANN). 

b) Repair/replacement activities of nuclear 
components shall meet the requirements of 



Section XI of the ASME Boiler and Pressure 
Vessel Code and the Jurisdiction where the 
nuclear power plant is located. 

c) Documentation of the repair/replacement 
activities of nuclear components shall be 
recorded on the National Board Report of 
Nuclear Repair/Modification or Replace- 
ment activities, Form NR-1, or Form NVR- 
1, as applicable. The completed forms 
shall be signed by a representative of the 
authorized nuclear repair organization 
and the Authorized Nuclear Inspector if 
the repair/replacement activity meets the 
requirements of ASME Section XI. For 
repair/replacement activities that involve 
design changes as specified in 1.8.5.1(c), 
Form NR-1 , or Form NVR-1 , as applicable, 

. shall indicate the responsible organization 
satisfying the owner's design specification 
requirements. 

d) The authorized nuclear repair organization 
shall provide a copy of the signed Form 
NR-1 or Form NVR-1, as applicable, to 
the owner, if required, the Jurisdiction, and 
the Authorized Nuclear Inspection Agency. 
The original Form NR-1 or Form NVR-1, 
as applicable, shall be registered with the 
National Board by the authorized nuclear 
repair organization. 

e) The authorized nuclear repair organization 
shall provide a nameplate/stamping for re- 
pair/replacement activities for each nuclear 
component unless otherwise required by 
the Owner's Quality System Program. The 
required information and format shall be 
as shown in Section 5 of this Part. 



4D 




Part 3, Section 2 

Repairs and Alterations — 

Welding and Heat Treatmen - 



4 i 



NATIONAL BOARD INSPECTION CODE • PART 3 — REPAIRS AND ALTERATIONS 

PART 3, SECTION 2 
REPAIRS AND ALTERATIONS — WELDING AND HEAT TREATMENT 



2.1 



SCOPE 



This section provides general and specific re- 
quirements for welding and heat treating when 
performing welded repairs and alterations to 
A07 pressure-retaining items. Careful consideration 
shall be given to pressure-retaining items that 
have been fabricated of either creep strength 
enhanced Icrritic materials or ferritic materials 
enhanced by heat treatment. The tensile and 
creep strength properties of these materials can 
be degraded by not following specific welding 
and heat treatment requirements. The user is 
cautioned to seek technical guidance for weld- 
ing and heat treating requirements in accor- 
dance with the original code of construction. 



2.2. 



WELDING 



Welding shall be performed in accordance 
with the requirements of the original code of 
construction used for the pressure-retaining 
item whenever possible. 



2.2.1 WELDING PROCEDURE 

SPECIFICATIONS 

Welding shall be performed in accordance 
with Welding Procedure Specifications (WPS) 
qualified in accordance with the original code 
of construction or the construction standard 
or code selected. When this is not possible or 
practicable, the WPS may be qualified in ac- 
cordance with Section IX of the ASME Code. 



2.2.2 STANDARD WELDING 

PROCEDURE SPECIFICATIONS 
(SEE 2.3) 

An "R" Certificate Holder may use one or more 
applicable Standard Welding Procedure Speci- 



fications (SWPS) shown in Table 2.3 without 
supporting Procedure Qualification Records 
(PQRs) since SWPS are pre-qualified. 



2.2.3 PERFORMANCE 

QUALIFICATION 

Welders and welding operators shall be quali- 
fied for the welding processes that are used. 
Such qualification shall be in accordance 
with the requirements of the original code of 
construction, the construction standard, code 
selected or Section IX of the ASME Code. Use 
of a Standard Welding Procedure Specifica- 
tion shown in 2.3 is permitted for performance 
qualification testing. 



2.2.4 



WELDING RECORDS 



The "R" Certificate Holder shall maintain 
a record of the results obtained in Welding 
Procedure Qualifications, except for those 
qualifications for which the provisions of 2.2.2 
are used and of the results obtained in welding 
performance qualifications. These records shall 
be certified by the "R" Certificate Holder and 
shall be available to the Inspector. 



2.2.5 



WELDERS' IDENTIFICATION 



The "R" Certificate Holder shall establish a 
system for the assignment of a unique identifi- 
cation mark to each welder/welding operator 
qualified in accordance with the requirements 
of the NBIC. The "R" Certificate Holder shall 
also establish a written procedure whereby 
welded joints are identified as to the welder 
or welding operator who made them. This pro- 
cedure shall use one or more of the following 
methods and be acceptable to the Inspector. 
The welder's or welding operator's identifica- 



42 



NATIONAL BOARD INSPECTION CODE • PART 3 



REPAIRS AND ALTERATIONS 



tion mark may be stamped (low stress stamp) 
adjacent to welded joints made by the indi- 
vidual or the "R" Certificate Holder may keep 
a documented record of welded joints and the 
welders or welding operators used in making 
the joints. 



2.2.6 



WELDERS' CONTINUITY 



The performance qualification of a welder or 
welding operator shall be affected when one 
of the following conditions occur: 

a) When the welder or welding operator has 
not welded using a specific process dur- 
ing a period of six months or more, their 
qualifications for that process shall expire. 
The "R" Certificate Holder shall maintain a 

A07 welding continuity record and shall make 
the record available to the Inspector. The 
method of recording welding continuity 
and the record retention period shall be 
described in the "R" Certificate Holder's 
Quality System Manual. 

b) When there is specific reason to question 
their ability to make welds that meet the 
specification, the qualification which sup- 
ports the welding that is being performed 
shall be revoked. All other qualifications 
not questioned remain in effect. 



units or metric units may be used for all SWPSs A07 
in Table 2.3, but one system shall be used for 
application of the entire SWPS in accordance 
with the metric conversation table contained in 
the SWPS. The user may issue supplementary 
instructions as allowed by the SWPS. Standard 
Welding Procedures Specifications shall not be 
used in the same product joint together with the 
other Standard Welding Procedures Specifica- 
tions or other welding procedure specifications 
qualified by the organization. 



2.3 STANDARD WELDING 

PROCEDURE SPECSFSCATIONS 

One or more (SWPSs) from Table 2.3 may be 
used as an alternative to one or more WPS 
documents qualified by the organization mak- 
ing the repair or alteration provided the orga- 
nization accepts by certification (contained 
therein) full responsibility for the application of 
the SWPS in conformance with the application 
as stated in the SWPS. When using SWPS's, all 
variables listed on the standard welding pro- 
cedure are considered essential and, therefore, 
the repair organization cannot deviate, modify, 
amend, or revise any SWPS's. US Customary 



43 



NATIONAL BOARD INSPECTION CODE • PART 3 



REPAIRS AND ALTERATIONS 



Table 2.3 

Carbon Steel — (P1 Materials) 



SMAW — Shielded Metal Arc Welding 



A08 



A08 



A08 



A08 



A08 



A08 



Standard Welding Procedure Specification for Shielded Metal Arc Welding of Carbon 
Steel, (M-1/P-1 , Croup 1 or 2), 3/1 6 in. (5 mm) through 3/4 in. (1 3 mm), in the As-Welried 
Condition, With Backing. 



Standard Welding Procedure Specification for Shielded Metal Arc Welding of Carbon Steel 
(M-1/P-1/S-1, Croup 1 or2), 1/8 in. (3.2 mm) through 1-1/2 in. (38 mm) Thick, E7018, As- 
Welded or PVVHT Condition. 



Standard Welding Procedure Specification for Shielded Metal Arc Welding of Carbon Steel 
(M-1/P-1/S-1, Croup 1 or 2), 1/8 in. (3.2 mm) through 1-1/2 in. (38 mm) Thick, E6010, As- 
Welded or PWHT Condition. 



Standard Welding Procedure Specification for Shielded Metal Arc Welding of Carbon Steel 
(M-1/P-1/S-1, Group 1 or 2), 1/8 in. (3.2 mm) through 1-1/2 in. (38 mm) Thick, E6010 
(Vertical Uphill) followed by E7018, As-Welded or PWHT Condition. 



Standard Welding Procedure Specification for Shielded Metal Arc Welding of Carbon Steel 
(M-1/P-1/S-1, Croup 1 or 2), 1/8 in. (3.2 mm) through 1-1/2 in. (38 mm) Thick, E6010 
(Vertical Downhill) followed by E7018, As-Welded or PWHT Condition. 



Standard Welding Procedure Specification for Shielded Metal Arc Welding of Carbon Steel 
(M-1/P-1/S-1, Croup 1 or 2), 1/8 in. (3.2 mm) through 3/4 in. (19 mm) Thick, E6010 
(Vertical Downhill) followed by E7018, (Vertical Uphill) As-Welded Condition, Primarily 
Pipe Applications. 



B2. 1.001 -90 

and 

B2. 1-1-001: 

90CR2OO6) 



B2. 1-1-016-94 

and 

B2.1-1-016-94R 



B2.1 -1-01 7-94 

and 

B2.1-1-017-94R 



B2.1 -1-022-94 

and 

B2.1-1-022-94R 



B2.1 -1-026-94 

and 

B2.1-1-026-94R 



Standard Welding Procedure Specification for Shielded Metal Arc Welding of Carbon Steel 
(M-1/P-1/S-1, Croup 1 or 2), 1/8 in. (3.2 mm) through 3/4 in. (19 mm) thick, 1-601.0 (Verti- 
cal Downhill; followed by E701 8 (Vertical Uphill), As-Welded Condition, Primarily Pipe 
Applications. 



Standard Welding Procedure Specification for Shielded Metal Arc Welding of Carbon Steel 
(M-1/P-1/S-1, Croup 1 or 2), 1/8 in. (3.2 mm) through 3/4 in. (19 mm) Thick, E6010 
(Vertical Uphill), As-Welded Condition, Primarily Pipe Applications. 



Standard Welding Procedure Specification for Shielded Metal Arc Welding of Carbon 
Steel (M-1/P-1/S-1, Croup 1 or 2), 1/8 in. (3.2 mm) through 3/4 in. (19 mm) Thick, E6010 
(Vertical downhill root with balance vertical uphill), As-Welded Condition, Primarily Pipe 
Applications. 



Standard Welding Procedure Specification for Shielded Metal Arc Welding of Carbon Steel 
(M-1/P-1/S-1, Group 1 or 2), 1/8 in. (3.2 mm) through 1-1/2 in. (38 mm) Thick, E6010 
(Vertical Uphill) followed by E701 8 (Vertical Uphill), As-Welded or PWHT Condition, 
Primarily Pipe Applications. 



B2.1 -1-201 -96, 
and B2. 1-1-201- 
96(R2007) 



B2. 1-1-202- 
96(R2007) 



B2.1 -1-203-96 
and B2.1 -1-203- 
96(R2007) 



B2. 1-1-204-96 
and B2. 1-1-204- 
96(R2007) 



Standard Welding Procedure Specification for Shielded Metal Arc Welding of Carbon Steel 
(M-1/P-1/S-1, Group 1 or 2), 1/8 in. (3.2 mm) through 3/4 in. (19 mm) Thick, E6010 
(Vertical Downhill) followed by E701 8 (Vertical Uphill), As-Welded or PWHT Condition, 
Primarily Pipe Applications. 



B2. 1-1-205-96 
and B2. 1-1 -205- 
96(R2007) 



B2. 1-1-206 96 
and B2. 1-1 -206- 
96(R2007) 



44 



NATIONAL BOARD INSPECTION CODE • PART 3 



REPAIRS AND ALTERATIONS 



A08 


Standard Welding Procedure Specification for Shielded Metal Arc Welding of Carbon Steel 
(M-1/P-1/S-1, Croup 1 or 2), 1/8 in. (1.2 mm) through 3/4 in. (19 mm) Thick, F7018, As- 
Welded or PWHT Condition, Primarily Pipe Applications. 


82.1-1-208-96 


A08 


Standard Welding Procedure Specification for Shielded Metal Arc Welding of Carbon Steel 
(M-1/P-1/S-1, Croup 1 or 2), 1/8 in. (3.2 mm) through '1-1/2 in. (38 mm) Thick, E7018, As- 
Welded or PWHT Condition, Primarily Pipe Applications. 


B2. 1-1-208- 
96(R2007) 




CTAW — Gas Tungsten Arc Welding 


A08 


Standard Welding Procedure Specification for Cas Tungsten Arc Welding of Carbon Steel, 
(M-1/P-1, Group 1 or 2), 3/16 in. (5 mm) through 7/8 in. (22 mm) Thick, in the As-Welded 
Condition, With or Without Backing. 


B2. 1-002-90, 
B2. 1-002- 
90(R2006) and 
B2.1-1-002-90R 




Standard Welding Procedure Specification for Cas Tungsten Arc Welding of Carbon Steel 
(M-1/P-1/S-1, Croup 1 or 2), 1/8 in. (.3.2 mm) through 3/4 in. (19 mm) Thick, ER70S-2, 
As-Welded or PWHT Condition, Primarily Pipe Application. 


B2. 1-1-207-96 


A08 


Standard Welding Procedure Specification for Cas Tungsten Arc Welding of Carbon Steel 
(M-l/P-l/S-1, Croup 1 or 2), 1/8 in. (.3.2 mm) through 1-1/2 in. (38 mm) Thick, ER70S-2, 
As-Welded or PWHT Condition, Primarily Pipe Application. 


B2. 1-1-207-96 
(R2007) 




Standard Welding Procedure Specification for Gas Tungsten Arc Welding (Consumable 
Insert) of Carbon Steel (M-l/P-l/S-1, Group 1 or 2), 1/8 in. (3.2 mm) through 3/4 in. 
(19 mm) Thick, INMsl and ER70S-2, As-Welded or PWHT Condition, Primarily Pipe 
Application. 


B2. 1-1-210-96 




Standard Welding Procedure Specification for Gas Tungsten Arc Welding with Consumable 
Insert Root of Carbon Steel (M-1/P-1/S-1, Group 1 or 2), 1/8 in. (3.2 mm) through 1-1/2 in. 
(38 mm) Thick, INMs-1, ER70S-2, As-Welded or PWHT Condition, Primarily Pipe 
Applications. 


B2.1 -1-21 0:2001 




FCAW — Flux Core Arc Welding 




Standard Welding Procedure Specification for Self-Shielded Flux Cored Arc Welding of 
Carbon Steel (M-l/P-l/S-1, Group 1 or 2), 1/8 in. (3.2 mm) through 1-1/2 in. (38 mm) 
I hick, E71T-8, As-Welded Condition. 


B2. 1-1 -01 8-94 

and 

B2.M.018-94R 




Standard Welding Procedure Specification for C02 Shielded Flux Cored Arc Welding of 
Carbon Steel (M-1/P-1/S-1, Group 1 or 2), 1/8 in. (3.2 mm) through 1-1/2 in. (38 mm) 
Thick, E70T-1 and E71T-1, As-Welded Condition. 


B2.1 -1-01 9-94 

and 

B2.1-1-019-94R 




Standard Welding Procedure Specification for 75% Ar/25% C02 Shielded Flux Cored Arc 
Welding of Carbon Steel (M-l/P-l/S-1, Group 1 or 2), 1/8 in. (3.2 mm) through 1-1/2 in. 
(38 mm) Thick, E70T-1M and F71T-1M, As-Welded or PWHT Condition. 


B2.1 -1-020-94 

and 

B2.1-1-020-94R 




Standard Welding Procedure for Self-Shielded Flux Cored Arc Welding of Carbon Steel 
(M-l/P-l/S-1, Group 1 or 2), 1/8 in. (3.2 mm) through 1/2 in. (13 mm) Thick, E71T-11, 
As-Welded Condition. 


B2. 1-1-027-1998 



45 



NATIONAL BOARD INSPECTION CODE • PART 3 



REPAIRS AND ALTERATIONS 



A07 



A07 



A07 



A07 



A08 



A07 



Standard Welding Procedure Specification (SWPS) for Argon Plus 25% Carbon Dioxide 
Shielded Flux Cored Arc Welding of Carbon Steel (M-1/P-1/S-1, Groups 1 and 2), 1/8 in. 
(3.2 mm) through 1-1/2 in. (38 mm) Thick, F7XT-XM, As-Welded or PWHT Condition, 
Primarily Pipe Applications. 


B2. 1-1-234: 
2006 


GMAW - Gas Metal Arc Welding 


Standard Welding Procedure Specification for Argon Plus 25% Carbon Dioxide Shielded 
Gas Metal Arc Welding (Short Circuiting Transfer Mode) followed by Argon Plus 2% 
Oxygen Shielded Gas Metal Arc Welding (Spray Transfer Mode) of Carbon Steel 
(M-1/P-1/S-1, Groups 1 and 2), 1/8 in. (3.2 mm) through 1-1/2 in. (38 mm) Thick, ER70S-3, 
Flat Position Only, As-Welded or PWHT Condition, Primarily Pipe Applications. 


B2.1 -1-233: 
2006 


Standard Welding Procedure Specification for Argon Plus 2% Oxygen Shielded Gas Metal 
Arc Welding (Spray Transfer Mode) of Carbon Steel (M-1/P-1/S-1 , Groups 1 and 2), 
1/8 in. (3.2 mm) through 1-1/2 in. (38 mm) Thick, FR70S-3, Flat Position Only, As- Welded 
or PWHT Condition, Primarily Pipe Applications. 


B2.1 -1-235: 
2006 


GTAW/SMAW Combination of Welding Processes 


Standard Welding Procedure Specification for Gas Tungsten Arc Welding Followed by 
Shielded Metal Arc Welding of Carbon Steel (M-1/P-1/S-1 , Group 1 or 2), 1/8 in. (3.2 mm) 
through 1-1/2 in. (38 mm! Thick, ER70S-2 and E701 8, As-Welded or PWI IT Condition. 


B2. 1-1-021-94 

and 

B2.1-1-021-94R 


Standard Welding Procedure Specification for Gas Tungsten Arc Welding followed by 
Shielded Metal Arc Welding of Carbon Steel (M-1/P-1/S-1, Groups 1 or 2), 1/8 in. 
(3.2 mm) through 3/4 in. (19 mm) Thick, ER70S-2 and E7018, As-Welded or PWHT 
Condition, Primarily Pipe Applications. 


B2.1 -1-209-96 


Standard Welding Procedure Specification for Gas Tungsten Arc Welding followed by 
Shielded Metal Arc Welding of Carbon Steel (M-1/P-1/S-1, Groups 1 or 2), 1/8 in. 
(3.2 mm) through 1-1/2 in. (38 mm) Thick, ER70S-2 and E7018, As-Welded or PWHT 
Condition, Primarily Pipe Applications. 


B2.1 -1-209-96 
(R2007) 


Standard Welding Procedure Specification for Gas Tungsten Arc Welding (Consumable 
Insert) Followed by Shielded Metal Arc Welding of Carbon Steel (M-1/P-1/S-1, Group 1 
or 2), 1/8 in. (3.2 mm) through 3/4 in. (19 mm) Thick, INMsl and E701 8, As-Welded or 
PWHT Condition, Primarily Pipe Applications. 


B2.1 -1-21 1-96 


Standard Welding Procedure Specification for Gas Tungsten Arc Welding with Consumable 
Insert Root Followed by Shielded Metal Arc Welding of Carbon Steel (M-1/P-1/S-1, Group 
1 or 2), 1/8 in. (3.2 mm) through 1-1/2 in. (38 mm) Thick, INMs-1, ER70S-2, and E7018 
As-Welded or PWHT Condition, Primarily Pipe Applications. 


B2. 1-1-21 1:2001 


GMAW/FCAW - Combination of Welding Processes 


Standard Welding Procedure Specification for Argon Plus 25% Carbon Dioxide Shielded 
Gas Metal Arc Welding (Short Circuiting Transfer Mode) Followed by Argon Plus 25% 
Carbon Dioxide Shielded Flux Cored Arc Welding of Carbon Steel (m-1/P-1/S-l, Groups 1 
and 2), 1/8 in. (3.2 mm) through 1-1/2 in. (38 mm) Thick, ER70S-3 and EXT-X, As-Welded 
or PWHT Condition, Primarily Pipe Applications. 


B2. 1-1-232:2006 



46 



NATIONAL BOARD INSPECTION CODE • PART 3 — REPAIRS AND ALTERATIONS 



Austenitic Stainless Steel — (M8/P8/S8Materials) 



A08 



SMAW — Shielded Metal Arc Welding 


Standard Welding Procedure Specification for Shielded Metal Arc Welding of Austenitic 
Stainless Steel (M-8/P-8/S-8, Croup 1), 1/8 in. (3.2 mm) through 1-1/2 in. (38 mm) Thick, 
As- Welded Condition. 


B2. 1-8-02-3-94 


Standard Welding Procedure Specification for Shielded Metal Arc Welding of Austenitic 
Stainless Steel (M-8/P-8/S-8, Croup 1), 1/8 in. (3.2 mm) through 1-1/2 in. (38 mm) Thick, 
E3XX-XX, As-Welded Condition, Primarily Pipe Application. 


B2. 1-8-213-97 
and B2. 1-8-213- 
96(R2007) 


CTAW — Gas Tungsten Arc Welding 


Standard Welding Procedure Specification for Cas Tungsten Arc Welding of Austenitic 
Stainless Steel (M-8/P-8/S-8, Croup 1), 1/8 in. (3.2 mm) through 1-1/2 in. (38 mm) Thick, 
As-Welded Condition. 


B2. 1-8-024-94 


Standard Welding Procedure Specification for Cas Tungsten Arc Welding of Austenitic 
Stainless Steel (M-8/P-8/S-8, Croup 1), 1/16 in. (1.6 mm) through 1-1/2 in. (38 mm) Thick, 
ER3XX, As-Welded Condition, Primarily Plate and Structural Applications. 


B2. 1-8-024:2001 


Standard Welding Procedure Specification for Cas Tungsten Arc Welding of Austenitic 
Stainless Steel (M-8/P-8/S-8, Group 1), 1/16 in. (1.6 mm) through 1-1/2 in. (38 mm) Thick, 
ER3XX, As-Welded Condition, Primarily Pipe Applications. 


B2. 1-8-212-97 


Standard Welding Procedure Specification for Cas Tungsten Arc Welding of Austenitic 
Stainless Steel (M-8/P-8/S-8, Croup 1), 1/16 in. (1 .6 mm) through 1-1/2 in. (38 mm) thick, 
ER3XX, As-Welded Condition, Primarily Pipe Applications. 


B2.1 -8-2 12:2001 


Standard Welding Procedure Specification for Cas Tungsten Arc Welding With 
Consumable Insert Root of Austenitic Stainless Steel (M-8/P-8/S-8, Croup 1), 1/8 in. 
(3.2 mm) through 1-1/2 in. (38 mm) Thick, IN3XX and ER3XX As-Welded Condition, 
Primarily Pipe Applications. 


B2. 1-8 215:2001 


Combination Processes GTAW/SMAW 


Standard Welding Procedure Specification for Cas Tungsten Arc Welding followed by 
Shielded Metal Arc Welding of Austenitic Stainless Steel (M-8/P-8/S-8, Croup 1), 1/8 in. 
(3.2 mm) through 1-1/2 in. (38 mm) Thick, As-Welded Condition. 


B2. 1-8-025-94 


Standard Welding Procedure Specification for Cas Tungsten Arc Welding followed by 
Shielded Metal Arc Welding of Austenitic Stainless Steel (M-8/P-8/S-8, Group 1), 1/8 in. 
(3.2 mm) through 1-1/2 in. (38 mm) Thick, ER3XX and E3XX-XX, As-Welded Condition, 
Primarily Plate and Structural Applications. 


B2. 1-8-025:2001 


Standard Welding Procedure Specification for Gas Tungsten Arc Welding Followed by 
Shielded Metal Arc Welding of Austenitic Stainless Steel (M-8/P-8/S-8, Group 1), 1/8 in. 
(3.2 mm) through 1 1/2 in. (38 mm) ['hick, ER3XX and E3XX-XX, As-Welded Condition, 
Primarily Pipe Applications. 


B2. 1-8-214-97 


Standard Welding Procedure Specification for Gas Tungsten Arc Welding Followed by 
Shielded Metal Arc Welding of Austenitic Stainless Steel (M-8/P-8/S-8, Group 1), 1/8 in. 
(3.2 mm) through 1-1/2 in. (38 mm) Thick, ER3XX and E3XX-XX, As-Welded Condition, 
Primarily Pipe Applications. 


B2. 1-8-214:2001 



47 



NATIONAL BOARD INSPECTION CODE • PART 3 



REPAIRS AND ALTERATIONS 



Standard Welding Procedure Specification for Gas Tungsten Arc Welding With 
Consumable Insert Followed by Shielded Metal Arc Welding of Austenitic Stainless Steel 
(M-8/P-8/S-8, Group 1), 1/8 in.' (3.2 mm) through 1-1/2 in. (3,8 mm) thick, IN3XX, FR3XX, 
and E3XX-XX As-Welded Condition, Primarily Pipe Application. 



B2. 1-8-216-1998 



Standard Welding Procedure Specification for Gas Tungsten Arc Welding with Consumable 
Insert Root followed by Shielded Metal Arc Welding of Austenitic Stainless Steel 
(M-8/P-8/S-8, Group 1), 1/8 in. (3.2 mm) through 1-1/2 in. (38 mm) Thick, I.N.3XX, ER3XX, 
and E3XX-XX As-Welded Condition, Primarily Pipe Applications. 



B2.1 -8-21 6:2001 



Combination of Carbon Steel (P-1 material) To Austenitic Stainless Steel (P-8 Material) 



SMAW — Shielded Metal Arc Welding 


Standard Welding Procedure Specifications for Shielded Metal Arc Welding of Carbon 
Steel (M-1/P-1/S-1, Groups 1 or 2) to Austenitic Stainless Steel (M-8/P-8/S-8, Group 1), 
1/8 in. (3.2 mm) through 1-1/2 in. (38 mm) Thick, E309(L)-15, -1 6, or -17, As-Welded 
Condition, Primarily Pipe Applications. 


B2. 1-1/8-228:2002 


GTAW — Gas Tungsten Arc Welding 


Standard Welding Procedure Specification for Gas Tungsten Arc Welding of Carbon 
Steel (M-1/P-1/S-1, Groups 1 or 2) to Austenitic Stainless Steel (M-8/P-8/S-8, Group 1), 
1/16 in. (1.6 mm) through 1-1/2 in. (38 mm) Thick, ER309(L), As-Welded Condition, 
Primarily Pipe Applications. 


B2. 1-1/8-227:2002 


Standard Welding Procedure Specifications for Gas Tungsten Arc Welding with 
Consumable Insert Root of Carbon Steel (M-1/P-1/S-1 , Groups 1 or 2) to Austenitic 
Stainless Steel (M-8/P-8/S-8, Group 1), 1/16 in. (1.6 mm) through 1-1/2 in. (38 mm) 
Thick, IN309 and ER309(L), As-Welded Condition, Primarily Pipe Applications. 


B2. 1-1/8-230:2002 


GTAW/SMAW Combination of Welding Processes 


Standard Welding Procedure Specifications for Gas Tungsten Arc Welding followed by 
Shielded Metal Arc Welding of Carbon Steel (M-1/P-1/S-1, Groups 1 or 2) to Austenitic 
Stainless Steel (M-8/P-8/S-8, Group 1), 1/8 in. (3.2 mm) through 1-1/2 in. (38 mm) 
Thick, ER309(L) and E309(L)-1 5, -1 6, or -1 7, As-Welded Condition, Primarily Pipe 
Applications. 


B2. 1-1/8-229:2002 


Standard Welding Procedure Specifications for Gas Tungsten Arc Welding with 
Consumable Insert Root followed by Shielded Metal Arc Welding of Carbon Steel 
(M-1/P-1/S-1, Groups 1 or 2) to Austenitic Stainless Steel (M-8/P-8/S-8, Group 1), 
1/8 in. (3.2 mm) through 1-1/2 in. (38 mm) Thick, IN3009, ER309, and E309-15, -16, or 
-1 7 or IN309, ER309(L) and ER309(L)-1 5, -1 6, or -1 7, As-Welded Condition, Primarily 
Pipe Applications. 


B2. 1-1/8-23 1:2002 



4B 



NATIONAL BOARD INSPECTION CODE • PART 3 — REPAIRS AND ALTERATIONS 



Chromium Molybdenum Steel (M4/P4 and M5a/P5A Materials) 



SMAW — Shielded Metal Arc Welding 


Standard Welding Procedure Specifications for Shielded Metal Arc Welding of 
Chromium-Molybdenum Steel (M-4/P-4, Croup 1 or 2), E8018-B2, 1/8 in. (3.2 mm) 
through 1-1/2 in. (38 mm) Ihick, As-Welded Condition, 1/8 in. (3.2 mm) through 
1-1/2 in. (38 mm) Thick, PWI IT Condition, Primarily Pipe Applications. 


B2. 1-4-218:1999 


Standard Welding Procedure Specifications for Shielded Metal Arc Welding of 
Chromium-Molybdenum Steel (M-5A/P-5A), E9018-B3, 1/8 in. (3.2 mm) through 
1-1/2 in. (38 mm)Thick, As-Welded Condition, 1/8 in. (3.2 mm) through 1-1/2 "in. 
(38 mm) Ihick, PWHT Condition, Primarily Pipe Applications. 


B2.1-5A-223:1999 


CTAW — Gas Tungsten Arc Welding 


Standard Welding Procedure Specifications for Gas Tungsten Arc Welding of 
Chromium-Molybdenum Steel (M-4/P-4, Group 1 or 2), ER80S-B2, 1/8 in. (3.2 mm) 
through 1-1/2 in. (38 mm) Thick, As-Welded Condition, 1/8 in. (3.2 mm) through 3/4 in. 
(19 mm) Thick, PWHT Condition, Primarily Pipe Applications. 


B2. 1-4-217:1999 


Standard Welding Procedure Specifications for Gas Tungsten Arc Welding (Consumable 
Insert Root) of Chromium-Molybdenum Steel (M-4/P-4, Group 1 or 2), E8018-B2, 
1/8 in. (3.2 mm) through 1-1/2 in. (38 mm) Thick, As-Welded Condition, 1/8 in. 
(3.2 mm) through 3/4 in. (19 mm) Thick, PWHT Condition, IN515 and ER80S-B2, 
Primarily Pipe Applications. 


B2. 1-4-220:1 999 


Standard Welding Procedure Specifications for Gas Tungsten Arc Welding of 
Chromium-Molybdenum Steel (M-5A/P-5A), ER90S-B3, 1/8 in. (3.2 mm) through 
1 -1/2 in. (38 mm) Thick, As-Welded Condition, 1/8 in. (3.2 mm) through 3/4 in. 
(19 mm) Thick, PWHT Condition, Primarily Pipe Applications. 


B2.1-5A-222:1999 


Standard Welding Procedure Specifications for Gas Tungsten Arc Welding (Consumable 
Insert Root) of Chromium-Molybdenum Steel (M-5A/P-5A), 1/8 in. (3.2 mm) through 
1-1/2 in. (38 mm) Thick, As-Welded Condition, 1/8 in. (3.2 mm) through 3/4 in. 
(1 9 mm) Thick, I'WHT Condition, IN52 1 and ER90S-B3, Primarily Pipe Applications. 


B2.1-5A-225:1999 


Chromium-Molybdenum Steel Processes GTAW/SMAW j 


Standard Welding Procedure Specifications for Gas Tungsten Arc Welding (Consumable 
Insert Root) followed by Shielded Metal Arc Welding of Chromium-Molybdenum Steel 
(M-4/P-4, Group 1 or 2), 1/8 in. (3.2 mm) through 1-1/2 in. (38 mm! Thick, As-Welded 
Condition, 1/8 in. (3.2 mm) through 1-1/2 in. (38 mm) Thick, PWHT Condition, IN515, 
ER80S-B2, and E8018-B2, Primarily Pipe Applications. 


B2. 1-4-221:1999 


Standard Welding Procedure Specifications for Gas Tungsten Arc Welded followed by 
Shielded Metal Arc Welding of Chromium-Molybdenum Steel (M-5A/P-5A), 1/8 in. 
(3.2 mm) through 1-1/2 in. (38 mm) Thick, As-Welded Condition, 1/8 in. (3.2 mm) 
through 1-1/2 in. (38 mm) Thick, PWHT Condition, FR90S-B3 and E9018-B3, Primarily 
Pipe Applications. 


B2.1-5A-224:1999 


Standard Welding Procedure Specifications for Gas Tungsten Arc Welding (Consumable 
Insert Root) followed by Shielded Metal Arc Welding of Chromium-Molybdenum Steel 
(M-5A/P-5A), 1/8 in. (3.2 mm) through 1-1/2 in. (38 mm) Thick, As-Welded Condition, 
1/8 in. (3.2 mm) through 1-1/2 in. (38 mm) Thick, PWHT Condition, IN521, ER90S-B3, 
and E9018-B3, Primarily Pipe Applications. 


B2.1-5A-226:1999 



49 



NATIONAL BOARD INSPECTION CODE • PART 3 — REPAIRS AND ALTERATIONS 



2.4 



AWS REFERENCE STANDARDS 



The following AWS Standards have been adopt- 
ed by the NBIC for use as referenced below: 

a) AWS B2.1 Specification for Welding Pro- 
cedure and Performance Qualification 

b) AWS B2.1 BMC — Base Metal Grouping 
for Welding Procedure and Performance 
Qualification 



2.5 



2.5.1 



HEAT TREATMENT 



PREHEATING 



Preheating may be employed during weld- 
ing to assist in completion of the welded 
joint. The need for and the temperature 
of preheat are dependent on a number of 
factors such as chemical analysis, degree 



of restraint of the items being joined, mate- 
rial thickness, and mechanical properties. 
The welding procedure specification for 
the material being welded shall specify the 
preheat temperature requirements. 

b) See minimum temperatures for preheating 
given in Table 2.5.1 as a general guide. It is 
cautioned that the preheating temperatures 
listed do not necessarily ensure satisfactory 
completion of the welded joint. Require- 
ments for individual materials within the 
P-Number listing may have preheating 
requirements more or less restrictive than 
this general guide. When reference is made 
in this section to materials by the ASME 
designation, P-Number and Group Num- 
ber, the suggestions of this Section apply 
to the applicable materials of the original 
code of construction, either ASME or other, 
which conform by chemical composition 
and mechanical properties to ASME materi- 
als having the ASME P-Number and Group 
Number designations. 



Table 2.5.1 

Minimum Temperatures for Preheating 



Thicknesses referenced are nominal at the weld for the parts to be joined. 


a) P-No. 1 Croup Nos. 1, 2, and 3 


1) 1 75°F (79°C) for material that has both a specified maxi- 

mum carbon content in excess of 0.30% and a thickness 
at the joint in excess of 1 in. 

2) 50"F (1 0°C) for all other materials in this P-Number. 


b) P-No. 3 Croup Nos. 1, 2, and 3 


1 ) 1 75°F (79°C) for material that has either a specified mini- 

mum tensile strength in excess of 70,000 psi (480 MPa) 
or a thickness at the joint in excess of 5/8 in. (16 mm). 

2) 50°F (10°C) for all other materials in this P-Number. 


c) P-No. 4 Croup Nos. 1 and 2 


1 ) 250 = F (1 20°C) for material that has either a specified mini- 

mum tensile strength in excess of 60,000 psi (410 MPa) 
or a thickness at the joint in excess of 1/2 in. (1 3 mm). 

2) SOT (1 = G for all other materials in this P-Number. 



5D 



NATIDNAL BOARD INSPECTION CODE • PART 3 



REPAIRS AND ALTERATIONS 



d) P-No. 5A Croup 1 and 5B, Croup 1 


1) 400T (205T") for material that has either a specified mini- 

mum tensile strength in excess of 60,000 psi (410 MPa) 
or has both a specified minimum chromium content 
above 6.0% and thickness at the joint in excess of 1/2 in. 
(13 mm). 

2) 300T (1 50°C) for all other materials in this P-Number. 


e! P-No. 6 Croup Nos. 1, 2, and 3 


400T (205°C) 


f) P-No. 7 Group Nos. 1 and 2 


None 


g! P-No. 8 Croup Nos. 1 and 2 


None 


h) P-No. 9 Croup 


1) 250°F (120°Q for P-9A Cr. 1 materials 

2) 300'F (1 50°C) for P-9B Gr. 1 materials 


i) P-No. 10 Group 


1 ) 1 75°F (79°C) for P-1 0A Cr. 1 materials 

2) 250°F (1 20°C) for P-1 0B Cr. 2 materials 

3) 175°F (79°C) for P-10C Gr. 3 materials 

4) 250> (120°C) for P-1 OF Gr. 6 materials 

5) For P-10C Gr. 3 materials, preheat is neither required nor 

prohibited, and consideration shall be given to the limita- 
tion of interpass temperature for various thicknesses to 
avoid detrimental effects on the mechanical properties of 
heat treated material. 

6) For P-10D Cr. 4 and P-1 0C Cr. 5 materials, 300°F (150°C) 

with interpass temperature maintained between 350°F 
and 450 = F (1 7.TC and 230°C). 


j) P-No. 1 1 Group 


1) P-1 1 A Croup 

Croup 1 - None (Note 1) 
Croup 2 - Same as for P-No. 5 (Note 1 ) 
Croup 3 - Same as for P-No. 5 (Note 1 ) 
Croup 4 -2.50°F (120*0 

2) P-1 1B Group 

Group 1 - Same as for P-No. 3 (Note 1 ) 
Group 2 - Same as for P-No. 3 (Note 1 ) 
Group 3 - Same as for P-No. 3 (Note 1 ) 
Group 4 - Same as for P-No. 3 (Note 1 ) 
Group 5 - Same as for P-No. 3 (Note 1 ) 
Croup 6 - Same as for P-No. 5 (Note 1) 
Croup 7 - Same as for P-No. 5 (Note 1 ) 


Note 1 : Consideration shall be given to the limitation of interpass temperature for various thicknesses to avoid 
detrimental effects on the mechanical properties of heat treated materials. 



5 1 



NATIONAL BOARD INSPECTION CODE • PART 3 



REPAIRS AND ALTERATIONS 



2.5.2 POSTWELD HEAT TREATMENT 

(PWHT) 

a) Postweld heat treatment shall be per- 
formed as required by the original code of 

A07 construction, the construction standard or 
code selected in accordance with a written 
procedure. The procedure shall contain the 
parameters for postweld heat treatment. 

b) When it is impractical or detrimental to 
postweld heat treat (PWHT) the entire item 
or band around the item, the following lo- 
cal PWHT method may be performed on 
spherical or cylindrical pressure-retaining 
items using the time and temperature pa- 
rameters in the original code of construc- 
tion and in accordance with a written 

A07 acceptance by the Inspector and, when 
required, by the Jurisdiction. 

1) Heat a local area around the nozzle, 
welded attachment, or repair area such 
thai the area is brought up uniformly 
to the required PWHT temperature. 
The application of local PWHT should 
be performed with controlled heating 
methods, such as induction or electric 
resistance heaters, and employing ther- 
A07 mocouples to monitor PWHT tempera- 

ture. The SB shall extend tangentially 
and radially from the edge of the nozzle 
wall, or attachment weld or repair area 
equally by a minimum distance as de- 
fined by the thickness of the shell, t or 
2 in. (50 mm), whichever is less. 

A07 Soak Band (SB) — this is the region 

on the spherical or cylindrical shell 
that will be heated uniformly to the 
required PWHT temperature. This band 
encompasses a circular region in the 
tangential and radial directions starting 
from the edge of a welded nozzle, or 
repair area or welded attachment that 
will be subjected to PWHT. 

A07 2) The length of the HB shall consist of 
the SB distance plus 4^R*t. In no case 
shall the distance of the HB that extends 
beyond the edge of the nozzle weld, 



attachment weld or repair area be less 
than 5\'R*t. 

Heating Band (HB) - this is the region A07 
that encompasses the application of 
heat for PWHT and is defined in length 
by the equation (SB+4\'R*t), where R 
is the outer radius of the spherical or 
cylindrical shell in inches (mm), and t 
is equal to the nominal thickness of the 
spherical or cylindrical shell in inches 
(mm). 

3) The CCB shall be kept as low as pos- A07 
sible in all directions to avoid harm- 
ful temperature gradients adjacent to A07 
nozzles or geometric discontinuities. 

Gradient Control Band (GCB) - this is A07 
the region that encompasses the SB, 
HB and extends beyond the edge of the 
HB. 

4) For PWHT of nozzle welds, repair 
welds, and external attachment welds 
on smooth spherical shells, heads, 
and cylindrical shells, the temperature 
differential within the GCB measured 
at the outside edge of the SB and the 
temperature measured at the outside 
edge of the HB shall not exceed one- A07 
half (1/2) of the peak soak PWHT tem- 
perature. 

5) The term t, or definition of thickness for 
calculating the holding time, for local 
PWHT shall be the nominal thickness 
of either a full penetration weld, or the 
groove weld depth of a partial penetra- 
tion repair weld. If a fillet weld is used 
in combination with a groove weld, the 
nominal thickness for PWHT shall be 

the depth of the groove weld. A07 



2.5.3 ALTERNATIVE WELDING 

METHODS WITHOUT POST- 
WELD HEAT TREATMENT 

a) Under certain conditions, postweld heat 
treatment, in accordance with the original 



52 



NATIONAL BOARD INSPECTION CODE • PART 3 



REPAIRS AND ALTERATIONS 



code of construction, may be inadvisable 
or impractical. In such instances, the fol- 
lowing alternative methods may be used. 

b) Competent technical advice shall be ob- 
tained from the manufacturer of the pres- 
sure-retaining item or from another quali- 
fied source, such advice being especially 
necessary if the alternative is to be used in 
highly stressed areas, if service conditions 
are conducive to stress corrosion cracking, 
if materials are subject to hydrogen embrit- 
tlement, or are operating at temperatures in 
the creep range, or if the alternative is being 
considered for "on-stream" repairs or "hot 
tapping" on piping systems. Selection of the 
welding method used shall be based on the 
rules of the original code of construction 
together with the above mentioned advice 
concerning the adequacy of the weld in 
the as-welded condition at operating and 
pressure test conditions. 

c) When reference is made in this Section to 
materials by the ASME designation, P-Num- 
ber and Croup Number, the requirements 
of this Section apply to the applicable 
materials of the original code of construc- 
tion, either ASME or other, which conform 
by chemical composition and mechanical 
properties to the ASME P-Number and 
Group Number designations. 

d) The detailed welding methods listed in 
the following subsections may be used as 
an alternative to postweld heat treatment 
(PWHT). Subsection 2.5.3.1 is a method 
in which the welding procedure requires 
an elevation of the preheat temperature. In 
contrast, 2.5.3.2 thru 2.5.3.5, are methods 
in which the welding procedure requires 
the use of a temper-bead welding tech- 
nique. In 2.5.4.5 is a method in which the 
welding procedure used for joining dissimi- 
lar materials requires either an elevation of 
the preheat temperature or a temper-bead 
welding technique, depending on the 
chemical composition of the base metal 
that is joined to an austenitic steel. Temper- 
bead welding procedure nomenclature is 
defined in Section IX of the ASME Boiler 



and Pressure Vessel Code. Typically, this 
technique minimizes heat input of the 
initial beads, thus limiting heat beyond the 
weld heat-affected zone (HAZ) of the base 
metal. Heat input shall be increased for 
successive beads in accordance with the 
rules of QW-290 for temper bead welding 
in Section IX of the ASME Boiler and Pres- 
sure Vessel Code. The welding procedure 
and welder performance qualifications 
shall, in all cases, be in accordance with 
the requirements of the latest edition and 
addenda of Section IX of the ASME Boiler 
and Pressure Vessel Code. 

e) Methods that may be used as alternatives 
to postweld heat treatment are described 
in the following subsections. 



2.5.3.1 WELDING METHOD 1 

When using this method, the following is re- 
quired: 

a) This method may be used when the ap- 
plicable rules of the original code of con- 
struction did not require notch toughness 
testing. 

b) The materials shall be limited to P-No. 1, 
Group 1, 2, and 3 and to P-No. 3, Croup 
I and 2 (excluding Mn-Mo steels in Group 
2), as permitted for welded construction by 
the applicable rules of the original code of 
construction. 

c) The welding shall be limited to the shielded 
metal-arc welding (SMAW), gas metal-arc 
welding (GMAW), fluxcored arc welding 
(FCAW), and gas tungsten-arc welding 
(GTAW) processes. 

d) The welders and welding procedures speci- 
fications shall be qualified in accordance 
with the applicable rules of the original 
code of construction, except that no post- 
weld heat treatment shall be applied to the 
lest coupon. 



53 



NATIONAL BDARD INSPECTION CODE • PART 3 



REPAIRS AND ALTERATIONS 



e) The weld area shall be preheated and main- 
tained at a minimum temperature of 300°F 
(1 49°C) during welding. The 300°F (1 49°C) 
temperature shall be checked to assure that 
4 in. (1 02 mm) of the material or four times 
the material thickness (whichever is greater) 
on each side of the groove (or full thickness 
of joint for a groove weld) is maintained at 
the minimum temperature during welding. 
The maximum interpass temperature shall 
not exceed 450°F (230°C). When the weld 
does not penetrate through the full thick- 
ness of the material, the minimum preheat 
and maximum interpass temperatures need 
only be maintained at a distance of 4 in. 
(102 mm) or four times the depth of the 
repair weld, whichever is greater, on each 
side of the joint. 



d) The welding procedures specifications shall 
be qualified in accordance with the temper 
bead procedure qualification requirements 
in QVV-290 of Section IX of the ASME Boiler 
and Pressure Vessel Code, and shall include 
the following additional requirements: 

1) For P-No. 1 Groups 1, 2, and 3 and P- 
No. 3 Groups 1 , 2, and 3, the minimum 
preheat temperature shall be 350°F 
(1 77°C), and the maximum interpass 
shall be450°F(232°C). 

2) For P-No. 9A, P-No. 10A, P-N'o. 10B, 
P-No. 1 0C, P-No. 1 1 A, or P-No. 1 1 B, 
the minimum preheat and interpass 
temperature requirements shall be 
in accordance with the guidelines in 
2.5.1. 



2.5.3.2 WELDING METHOD 2 

When using this method, the following is re- 
quired: 

a) This method shall be used when the ap- 
plicable rules of the original code of con- 
struction required notch toughness testing 
or shall be used when the applicable rules 
of the original code of construction did not 
require notch toughness testing provided 
the adequacy of the notch toughness of the 
weld, including the heat-affected zone, in 
the as-welded condition at operating and 
pressure test conditions is verified. 

b) The materials shall be limited to carbon 
and low alloy steels permitted for welded 
construction by the applicable rules of the 
original code of construction, including those 
materials conforming to any of the following 
ASME P-No. designations: P-No. 1, Group 
1 ,2, and 3, P-No. 3, Group 1 , 2, and 3, P-No. 
4, P-No. 5A, P-No. 9A, P-No. 10A, P-No. 
1 0B, P-No. 1 0C, P-No. 1 1 A, or P-No. 1 1 B. 

c) The welding shall be limited to the Shielded 
Metal-Arc Welding (SMAW), Gas Metal -Arc 
Welding (GMAW), Fluxcored Arc Welding 
(FCAW), and Gas Tungsten-Arc Welding 
(GTAW) processes. 



3) For P-No. 4 and P-No. 5A materials, 
the minimum preheat, interpass tem- 
perature, and technique shall be in 
accordance with 2.5.3.4. The repair 
depth for temper bead repairs to P-No. 
4 and P-No. 5A materials shall be in 
accordance with the requirements of 
2.5.3.4(a) . 

c) The test material for the welding procedure 
qualification shall be of the same mate- 
rial specification (including specification 
type, grade, class, and condition of heat 
treatment) as the material being repaired. 
In the event that the notch toughness of 
the material to be repaired is unknown, 
evidence from tests of that material or from 
another acceptable source (see 2.5.3) may 
be used for the base metal notch tough- 
ness when qualifying the WPS as required 
in 2.5.3.2(h). In the event that the original 
material specification is obsolete, the test 
material used should conform as closely as 
possible to the original material used for 
construction based on nominal composi- 
tion and carbon equivalent (IIW Formula), 7 



7 The IIW Carbon bquivalent Formula is Cr= C.+ Mn/fi + 
;CrT-Mo+V)/."j + (NirCu)/15. Elements are expressed in Weight 
Percent Amounts. 



54 



NATIONAL BOARD INSPECTION CODE • PART 3 



REPAIRS AND ALTERATIONS 



but in no case shall the material be lower 
in strength. 

f) The qualification thickness for the test 
plates and repair groove depths shall be in 
accordance with Table 2.5.3. 

g) The organization making the repair shall 
include, when qualifying its WPS, sufficient 
tests to determine that the notch toughness 
of the weld metal and the heat-affected 
zone of the base metal in the as-welded 
condition is adequate at the minimum 
operating and pressure test temperatures 
(including start-up and shutdown). If for 
reasons of corrosion resistance, special 
hardness limits are necessary, such limits 
shall be included when qualifying the 
WPS. 

h) Notch toughness shall be determined and 
evaluated by Charpy impact tests in accor- 
dance with the provisions of the original 
code of construction at the temperature 
determined in accordance with 2.5.3.2(d). 
Exemptions from impact testing described 
in the original code of construction are not 
applicable. 

i) For the welding process in 2.5.3.2(c), use 
only electrodes and filler metals that are 
classified by the filler metal specification 
with a diffusible-hydrogen designator of 
H8 or lower. When shielding gases are 
used with a process, the gas shall exhibit a 
dew point that is below -60°F (-50°C). Sur- 
faces on which welding will be done shall 
be maintained in a dry condition during 
welding and be free of rust, mill scale, and 
hydrogen producing contaminants such as 
oil, grease, and other organic materials. 

j) After the weld has been deposited flush 
with the base metal, a surface temper re- 
inforcing weld layer shall be applied. 

k) For welds made by SMAW and FCAW, 
after completion of welding and without 
allowing the weldment to cool below the 
minimum preheat temperature, the tem- 
perature of the weldment shall be raised to 



a temperature of 450°F (232°C) minimum 
for a minimum period of two hours. This 
hydrogen bake-out treatment may be omit- 
ted provided the electrode used is classi- 
fied by the filler metal manufacturer with a 
diffusible-hydrogen designator of H4 (e.g., 
E7018-H4). 

I) After the finished repair weld has cooled 
to ambient temperature, the surface temper 
reinforcing layer shall be removed sub- 
stantially flush with the surface of the base 
material. 



2.5.3.3 



WELDING METHOD 3 



When using this method, the following is re- 
quired: 

a) This method may be used when the applica- 
ble rules of the original code of construction 
did not require notch toughness testing. 

b) The materials shall be limited to any P-No. 1 
or P-No. 3 material as permitted for welded 
construction by the applicable rules of the 
original code of construction. 

c) The welding shall be limited to the SMAW, 
FCAW, and GTAW processes. 

d) The test material for the welding procedure 
qualification shall be of the same P-No. 
and Group No. as the base material speci- 
fication of the repair. In the event that the 
original material specification is obsolete, 
the test material used should conform to the 
nominal composition and carbon equiva- 
lent (IIW Formula) as the material being 
repaired, but in no case shall the material 
be lower in strength. 

e) If for reasons of corrosion resistance, special 
hardness limits are necessary, such limits shall 
be included when qualifying the WPS. 



8 The IIW Carbon Equivalent Formula is CE= C- Mn/6 + 
(Cr+Mo+V)/ 1 ) + (Ni-Cu)/1 5. Elements are expressed in Weight 
Percent Amounts. 



55 



NATIONAL BOARD INSPECTION CODE • PART 3 



REPAIRS AND ALTERATIONS 



f) The qualification thickness for the test 
plates and repair groove depths shall be in 
accordance with Table 2.5.3. 

g) The WPS shall be qualified in accordance 
with the temper bead procedure qualifica- 
tion requirements in QW-290 of Section 
IX of the ASME Boiler and Pressure Vessel 
Code, and shall include the following ad- 
ditional requirements: 

1 ) The minimum preheat temperature for 
welding shall be 350°F (1 77° C) and the 
maximum interpass temperature shall 
be450°F(232°C). 

2) For the welding processes in 2.5.3.3(c), 
only electrodes or filler metals that are 
classified by the filler metal specifica- 
tion with a diffusible-hydrogen designa- 
tor of H8 or lower may be used. When 
shielding gases are used with a process, 
the gas shall exhibit a dew point that 
is below -60°F (-50°C). Surfaces on 
which welding will be done shall be 
maintained in a dry condition during 
welding and be free of rust, mill scale, 
and hydrogen producing contaminants 
such as oil, grease, and other organic 
materials. 

3) After completion of welding using 
SMAW and without allowing the 
weldment to cool below the minimum 
preheat temperature, the temperature 
of the weldment shall be raised to a 
temperature of 450 C F (232 C C) minimum 
for a minimum period of two hours. 
This hydrogen bake-out treatment may 
be omitted provided the electrode used 
is classified by the filler metal manu- 
facturer with a diffusible-hydrogen 
designator of H4 (e.g., E7018-H4). 

4) After the finished repair weld has 
cooled to ambient temperature, the 
final temper bead reinforcement layer 
shall be removed substantially flush 
with the surface of the base material. 



2.5.3.4 



WELDING METHOD 4 



When using this method, the following is re- 
quired: 

a) This method is limited to repair welds in 
pressure-retaining items containing defects 
not penetrating through the full thickness 
for which the applicable rules of the origi- 
nal code of construction did not require 
notch toughness testing. 

b) The materials shall be limited to P-No. 4, 
Groups 1 and 2, and P-No. 5A steels as 
permitted for welded construction by the 
applicable rules of the original code of 
construction. 

c) The welding shall be limited to the SMAW, 
FCAW, GMAW or GTAW processes using 
low-hydrogen electrodes and filler metals A08 
classified by the filler metal specification 
with a diffusible-hydrogen designator of 

H8 or lower, and suitably controlled by 
maintenance procedures to avoid contami- 
nation by hydrogen producing sources. The 
surface of the metal prepared for welding 
shall be free of contaminants. 

d) The test material for the welding procedure 
qualification shall be of the same P-No. and 
Group No. as the original material specifi- 
cation for the repair. In the event that the 
original material specification is obsolete, 
the test material used shall conform to the 
nominal composition and carbon equiva- 
lent (IIW formula) q as the original material 
used for construction, and in no case shall 
the material be lower in strength. 

e) If for reasons of corrosion resistance, spe- 
cial hardness limits are necessary, such 
limits shall be included when qualifying 
the WPS. 

f) The qualification thickness for the test 



'J I he IIW Carbon equivalent Rirmula is CL=C.+ Mn/6 + 
(Cr+Mo+V)/5 + (\i-Cu)/15. blements are expressed in Weight 
Percent Amounts 



56 



NATIDNAL BOARD INSPECTION CODE • PART 3 — REPAIRS AND ALTERATIONS 



A08 g) 



plates and repair groove depths shall be in 2) 

accordance with Table 2.5.3. 

The welding procedures (WPS) shall be 
qualified in accordance with the temper 
bead procedure qualification requirements 
in QVV-290 of Section IX of the ASME Boiler 
and Pressure Vessel Code, and shall include 
the following additional requirements: 

1) The minimum preheat temperature 
for welding shall be 300°F (1 SOX) for 
P-No. 4 material and 400°F (200°C) for 
P-No. 5 A material. The preheat tem- 
perature shall be checked to ensure that 3) 
4 in. (102mm) of the material or four 
times the material thickness (whichever 
is greater) on each side of the groove 
(or full thickness of joint for a groove 
weld) is maintained at the minimum 4) 
temperature during welding. The in- 
terpass temperature shall not exceed 
800 C F (430°C). When the weld does not 
penetrate through the full thickness of 
the material, the minimum preheat and 
maximum interpass temperature need 
only be maintained for 4 in. (102mm) or 
four times the depth of the repair weld 
(whichever is greater) on each side of 
the joint. 



TABLE 2.5.3 



For the welding processes in 2.5.3.4(c), 
use only electrodes or filler metals that 
are classified by the filler metal specifi- 
cation with a diffusible-hydrogen des- 
ignator of H8 or lower. When shielding 
gases are used with a process, the gas 
shall exhibit a dew point that is below 
-60°F (-50°C). Surfaces on which weld- 
ing will be done shall be maintained in 
a dry condition during welding and be 
free of rust, mill scale, and hydrogen 
producing contaminants, such as oil, 
grease, and other organic materials. 

After the weld has been deposited 
flush with the base metal, a surface 
temper reinforcing weld layer shall be 
applied. 

For welds made by the SMAW and 
FCAW processes, after completion A08 
of welding and without allowing the 
weldment to cool below the minimum 
preheat temperature, the temperature of 
the weldment shall be raised to 450°F 
(232°C) minimum for a minimum peri- 
od of two hours. This hydrogen bake-out 
treatment may be omitted provided the 
electrode used is classified by the filler 
metal manufacturer with a diffusible- 
hydrogen designator of 1 14 (e.g., E701 8 
H4). 



Base Metal 
Thickness 


Repair 
Groove Depth 


PQRTest 

Material Thickness 


PQR Groove 
Depth (Note 2) 


Thickness 
Qualified (NoteD 


< 2 in. (50 mm) 


< 1 in. (25 mm) 


1 in. (25 mm) 


< 1 in. (25 mm) 


See PQR test 
material thickness 
column 


2 in. (50 mm) 


> 1 in. (25 mm) 


Thickness of the 
base metal to be 
repaired 


> 1 in. (25 mm) 


PQR test material 
thickness 


> 2 in. (50 mm) 


1 in. (25 mm) 


2 in. (50 mm) 


1 in. (25 mm) 


All base metal 
thickness and 
1 in. (25 mm) 
repair groove 
depth 


2 in. (50 mm) 


> 1 in. (25 mm) 


2 in. (50 mm) 


> 1 in. (25 mm) 


All haso metal 
thickness and PQR 
groove depth 


Note 1 : Repair groove depth is limited to the maximum depth qualified. 

Note 2: The depth of the groove used for procedure qualification must be deep enough to remove test specimens. 



57 



NATIONAL BOARD INSPECTION CODE • PART 3 



REPAIRS AND ALTERATIONS 



5) After the finished repair weld has 
cooled to ambient temperature, the 
surface temper reinforcing weld layer 
shall be removed substantially flush 
with the surface of the base metal (and 
for a fillet weld to the required size and 
suitable contour of the toes). 



2.5.3.5 WELDING METHOD 5 

When using this method, the following is re- 
quired: 

a) This welding method may be used when 
the applicable rules of the original code of 
construction or the construction standard or 
code selected permit joining dissimilar ma- 
terials used in pressure-retaining items. 

b) The materials shall be limited to ASME P- 
No. 1 , Croups 1 , 2, and 3, P-No. 3, Groups 
1, 2, and 3, P-No. 4, P-No. 5A, P-No. 9A, 
P-N'o. 10A, P-No. 10B, P-No. 10C, P-No. 
1 1 A, P-No. 1 1 B joined to either P-No. 8, P- 
No. 42, P-No. 43, or P-No. 45, as permitted 
for welded construction by the applicable 
rules of the original code of construction. 

c) The welding shall be limited to the SMAW, 
FCAW, GMAW and machine or automatic 
GTAW processes. The filler metal used 
for joining the dissimilar materials shall 
be either A-No 8 or Nickel-Chrome alloy 
classification (F-No 43). When selecting a 
filler metal for dissimilar metal weld joints, 
determine if the weld joint will be exposed 
to elevated temperature service. A-No 8 
filler metals exposed to service tempera- 
tures greater than 800°F (427°C) will exhibit 
reduced creep life along the fusion zone of 
the ferritic material due to carbon diffusion. 
Instead, a low hydrogen, Nickel-Chromium 
alloy classification filler metal shall be used 
for dissimilar weld joints exposed to service 
temperatures at or above 800°F (427°C). 

d) The WPS shall be qualified in accordance 
with the temper bead rules of QW-290 in 
Section IX of the ASME Boiler and Pressure 
Vessel Code. 



e) If the original code of construction did not 
require notch toughness testing, qualifi- 
cation of welding procedures (WPS) for 
joining ASME P-No. 1, P-No. 3 ferritic 
materials to either P-No. 8, P-No. 42, P-No. 
43, or P-No. 45 materials shall be in accor- 
dance with requirements in either 2.5.3.1, 
Welding Method I or in 2.5.3.3, Welding 
Method 3. 

f) If the original code of construction did not 
require notch toughness testing, qualifica- 
tion of welding procedures (WPS) for join- 
ing ASMF P-No. 4, P-No. 5A ferritic materi- 
als to either P-No. 8, P-No. 42, P-No. 43, 
P-No. 45 materials shall be in accordance 
with the requirements in 2.5.3.4, Welding 
Method 4. 

g) If the original code of construction required 
notch toughness testing, qualification of 
welding procedures (WPS) for joining fer- 
ritic materials to either P-No. 8, P-No. 42, 
P-No. 43, or P-No. 45 materials shall be 
in accordance with the requirements in 
2.5.3.2, Welding Method 2. 



58 




Part 3, Section 3 

Repairs and Alterations — 

Requirements for Repairs and 

Alterations 



59 



NATIONAL BOARD INSPECTION CODE • PART 3 — REPAIRS AND ALTERATIONS 

PART 3, SECTION 3 

REPAIRS AND ALTERATIONS — REQUIREMENTS FOR 

REPAIRS AND ALTERATIONS 



A07 3.1 



SCOPE 



This section provides general and specific 
requirements for materials, replacement parts, 
and methods used when performing repairs and 
alterations to pressure-retaining items. Specific 
repair or alteration methods for other types of 
pressure equipment are in Section 6, Supple- 
ments 1 thru 7 of this Part. 



3.2 GENERAL REQUIREMENTS FOR 

REPAIRS AND ALTERATIONS 



b) For corrugating rolls manufactured per the 
requirements of paragraph UF-7 of Section 
VIII, Div. 1, restoration of worn corrugating 
roll surfaces by weld overlay is permitted 
for all classes of SA-649 forging material 
and an exception to the 0.35% carbon limit 
is permitted. The requirements to qualify 
welding procedures and welder perfor- 
mance shall be in accordance with ASME 
Section IX for hard facing (wear resistance) 
and corrosion resistant overlays. 



3.2.2 



REPLACEMENT PARTS 



A07 3.2.1 MATERIAL REQUIREMENTS FOR 

REPAIRS AND ALTERATIONS 

a) The materials used in making repairs or 
alterations shall conform insofar as possible 
to the original code of construction or con- 
struction standard or code selected includ- 
ing the material specification requirements 
used for the work planned. Carbon or alloy 
steel having a carbon content of more than 
0.35% shall not be welded unless permitted 
by the original code of construction. The 
"R" Certificate Holder is responsible for 
verifying identification of existing materials 
from original data, drawings, or pressure- 
retaining item records, and identification of 
the materials to be installed. Consideration 
shall be given to the condition of the exist- 
ing material, especially in the weld prepa- 
ration area. If the existing material cannot 
A07 be verified (unknown), the "R" Certificate 
Holder shall perform a chemical analysis 
and hardness testing, as a minimum, of the 
unknown material to verify its weldability 
and strength or may elect to qualify a weld 
procedure. If there is a question with regard 
to the weldability characteristics of the 
material, then competent technical advice 
should be obtained. 



Replacement parts to be used in repairs or 
alterations shall meet the following applicable 
requirements: 

a) Replacement parts that will be subject to 
internal or external pressure that consist of 
new materials which should be formed to 
the required shape by casting, spinning, 
forging, die forming, and on which no 
fabrication welding is performed shall be 
supplied as material. Such parts shall be 
marked with the material and part identi- 
fication and the name or trademark of the 
parts manufacturer. In lieu of full identifi- 
cation marking on the material or part, the 
part manufacturer may use a coded marking 
system traceable to the original marking. 
Such markings shall be considered as the 
parts manufacturer's certification that the 
part complies with the original code of 
construction. Examples include seamless 
or welded tubes or pipe, forged nozzles, 
heads or tubesheets, or subassemblies at- 
tached together mechanically. 

b) Replacement parts that will be subject to 
internal or external pressure that are preas- 
sembled by attachment welds shall have the 
welding performed in accordance with the 



6Q 



NATIONAL BOARD INSPECTION CODE • PART 3 



REPAIRS AND ALTERATIONS 



original code of construction. The supplier 
or manufacturer shall certify that the mate- 
rial and fabrication are in accordance with 
the original code of construction. This certi- 
fication shall be supplied in the form of bills 
of material and drawings with statement 
of certification. Examples include boiler 
furnace wall or floor panel assemblies, 
prefabricated openings in boiler furnace 
walls, such as burner openings, air ports, 
inspection openings, or sootblower open- 
ings. 

c) When ASME is the original code of con- 
struction, replacement parts subject to 
internal or external pressure fabricated by 
welding, which require inspection by an 
Authorized Inspector shall be fabricated 
by an organization having an appropriate 
ASME Certificate of Authorization. The item 
shall be inspected and stamped as required 
by the applicable section of the ASME 
Code. A completed ASME Manufacturer's 
Partial Data Report shall be supplied by the 
manufacturer. 

A08 The "R" certificate holder using replace- 
ment parts fabricated and certified to an 
ASME code edition and addenda different 
from that used for the original construction 
shall consider and seek technical advice, 
where appropriate, for change or conflicts 
in design, materials, welding, heat treat- 
ment, examinations and tests to assure a 
safe repair/alteration is performed. Note 
that work once classified as a repair could 
now be considered an alteration. 

d) When the original code of construction is 
other than ASME, replacement parts subject 
to internal or external pressure, fabricated 
by welding shall be manufactured by an 
organization certified as required by the 
original code of construction. The item shall 
be inspected and stamped as required by 
the original code of construction. Certifi- 
cation to the original code of construction 
as required by the original code of con- 
struction or equivalent shall be supplied 
with the item. When this is not possible or 



practicable, the organization fabricating A08 
the part shall have a National Board "R" 
Certificate of Authorization; replacement 
parts shall be documented on Form R-3 and 
the "R" symbol stamp applied as described 
in Section 5 of this Part. 



3.2.3 



DRAWINGS 



As appropriate, drawings shall be prepared to A07 
describe the repair or alteration. Drawings shall 
include sufficient information to satisfactorily 
perform the repair or alteration. 



3.2.4 DESIGN REQUIREMENTS FOR 

REPAIRS AND ALTERATIONS 

a) Many repairs may not require drawings A07 
or design calculations when the original 
code of construction is known and draw- 
ings and/or a manufacturers data report is 
available. 

b) The "R" Certificate Holder performing A07 
repairs and alterations shall establish the 
construction standard or code and sufficient 
controls to ensure that all required design 
information, applicable drawings, design 
calculations, specifications, and instruc- 
tions are prepared, obtained, controlled, 
and interpreted to provide the basis for a 
repair or an alteration in accordance with 

the original code of construction. When 
a Manufacturers Data Report is required 
by the original construction standard, a 
copy of the original Data Report shall be 
obtained, where available, for use in the A07 
design of the repair or alteration. When 
the original Manufacturer's Data Report 
cannot be obtained, agreements on the 
method of establishing design basis for the 
repair or alteration shall be obtained from 
the Inspector and the Jurisdiction, when A07 
required. 



6 1 



NATIONAL BOARD INSPECTION CODE • PART 3 



REPAIRS AND ALTERATIONS 



3.2.5 



CALCULATIONS 



A07 For alterations, calculations shall be completed 
prior to the start of any physical work. All design 
calculations shall be completed by an organiza- 
tion experienced in the design portion of the 
standard used for construction of the item. All 
calculations shall be made available for review 
by the Inspector accepting the design. 



A07 3.3 



3.3.1 



REPAIRS TO PRESSURE- 
RETAINING STEMS 



DEFECT REPAIRS 



Before a repair is made to a defect in a welded 
joint or base metal, care should be taken to 
investigate its cause and to determine its extent 
and likelihood of recurrence. 



3.3.2 



ROUTINE REPAIRS 



a) Routine repairs are repairs for which the 
requirements for in-process involvement 
by the Inspector and stamping by the "R" 
Certificate Holder may be waived as de- 
termined appropriate by the Jurisdiction 
and the Inspector. All other applicable 
requirements of this Code shall be met. 
Prior to performing routine repairs, the 
"R" Certificate Holder should determine 
that routine repairs are acceptable to the 
Jurisdiction where the pressure-retaining 
item is installed. 

b) The Inspector, with the knowledge and un- 
derstanding of jurisdictional requirements, 
shall be responsible for meeting jurisdic- 
tional requirements and the requirements 
of this Code. 

c) The "R" Certificate Holder's quality system 
program shall describe the process for 
identifying, controlling, and implement- 
ing routine repairs. Routine repairs shall 
be documented on Form R-1 with this 
statement in the Remarks section: "Routine 
Repair." 



d) Repairs falling within one or more of the 
following categories may be considered 
routine: 

1) Welded repairs or replacements of 
valves, fittings, tubes, or pipes NPS 5 
(DN 125) in diameter and smaller, or 
sections thereof, where neither post- 
weld heat treatment nor NDE other 
than visual is required by the original 
code of construction. This includes their 
attachments such as clips, lugs, skirts, 
etc., but does not include nozzles to 
pressure-retaining items. 

2) The addition or repair of nonload bear- 
ing attachments to pressure-retaining 
items where postweld heat treatment 
is not required. 

3) Weld buildup of wasted areas not 
exceeding an area of 100 sq. inches 
(64,520 sq. mm) or a thickness of 25% 
of nominal wall thickness or Vi inch (1 3 
mm), whichever is less. 

4) Corrosion resistance weld overlay 
not exceeding 100 sq. in. (64,520 sq. 
mm). 



3.3.3 



EXAMPLES OF REPAIRS 



a) Weld repairs or replacement of pressure 
parts or attachments that have failed in a 
weld or in the base material; 

b) The addition of welded attachments to pres- 
sure parts, such as: 

1 ) Studs for insulation or refractory lining 

2) Hex steel or expanded metal for Refrac- 
tory lining 

3) Ladder clips 

4) Brackets having loadings that do not af- 
fect the design of the pressure-retaining 
item to which they are attached 



62 



NATIONAL BOARD INSPECTION CODE • PART 3 



REPAIRS AND ALTERATIONS 



5) Tray support rings. 

c) Corrosion resistant strip lining, or weld 
overlay; 

d) Weld buildup of wasted areas; 

e) Replacement of heat exchanger tubesheets 
in accordance with the original design; 

f) Replacement of boiler and heat exchanger 
tubes where welding is involved; 

g) In a boiler, a change in the arrangement 
of tubes in furnace walls, economizer, or 
super heater sections; 

h) Replacement of pressure-retaining parts 
identical to those existing on the pressure- 
retaining item and described on the original 
Manufacturer's Data Report. For example: 

1) Replacement of furnace floor tubes 
and/or sidewall tubes in a boiler 

2) Replacement of a shell or head in ac- 
cordance with the original design 

3) Rewelding a circumferential or longi- 
tudinal seam in a shell or head 

4) Replacement of nozzles of a size where 
reinforcement is not a consideration 

i) Installation of new nozzles or openings of 
such a size and connection type that re- 
inforcement and strength calculations are 
not a consideration required by the original 
code of construction; 

j) The addition of a nozzle where reinforce- 
ment is a consideration may be considered 
to be a repair provided the nozzle is identi- 
cal to one in the original design, located in 
a similar part of the vessel, and not closer 
than three times its diameter from another 
nozzle. The addition of such a nozzle shall 
be restricted by any service requirements; 

k) The installation of a flush patch to a pres- 
sure-retaining item; 



I) The replacement of a shell course in a cy- 
lindrical pressure vessel; 

m) Welding of gage holes; 

n) Welding of wasted or distorted flange 
faces; 

o) Replacement of slip-on flanges with weld 
neck flanges or vice-versa; 

p) Seal welding of buttstraps and rivets; 

q) Subject to the administrative procedures of 
thejurisdiction and approval of the Inspec- 
tor, the replacement of a riveted section or 
part by welding; 

r) The repair or replacement of a pressure part 
with a code accepted material that has a 
nominal composition and strength that is 
equivalent to the original material, and is 
suitable for the intended service; and 

s) Replacement of a pressure-retaining part 
with a material of different nominal com- 
position, equal to or greater in allowable 
stress from that used in the original design, 
provided the replacement material satisfies 
the material and design requirements of the 
original code of construction under which 
the vessel was built. The minimum required A08 
thickness shall be at least equal to the thick- 
ness stated on the original Manufacturer's 
Data Report. 



3.3.4 



REPAIR METHODS 



3.3.4.1 SCOPE 

A repair of a defect in a welded joint or base 
material shall not be made until the defect 
has been removed. A suitable Nondestructive 
Examination (NDE) method such as Magnetic 
Particle (MT) or I iquid Penetrant (PT) may be 
necessary to ensure complete removal of the 
defect. If the defect penetrates the full thickness 
of the material, the repair shall be made with a 
full penetration weld such as a double buttweld 



S3 



NATIONAL BOARD INSPECTION CODE • PART 3 — REPAIRS AND ALTERATIONS 



or single buttweld with or without backing. b) 
Where circumstances indicate that the defect 
is likely to recur, consideration should be given 
to removing the defective area and installing a 
flush patch or taking other, corrective measures 
acceptable to the Inspector and when required 
by the Jurisdiction. 



3.3.4.2 DEFECT REPAIRS 

Before a repair is made to a defect in a welded 
joint or base metal, care should be taken to 
investigate its cause and to determine its extent 
and likelihood of recurrence. d) 

a) Cracks 

A repair of a crack in a welded joint or base 
material shall not be made until the defect 
has been removed. A suitable nondestruc- 
tive examination method such as a MT or 
PT may be necessary to ensure complete re- 
moval of the defect. If the defect penetrates 
the full thickness of the material, the repair 
shall be made with a full penetration weld e) 
such as a double butt weld or single butt 
weld with or without backing, as allowed 
by the original code of construction. 



Unstayed Boiler Furnace Cracks 
Cracks at the knuckle or at the turn of the 
flange of the furnace opening require im- 
mediate replacement of the affected area or 
specific approval of repairs by the Jurisdic- 
tion. (See Figure 3.3.4.2-a). 

Rivet or Staybolt Hole Cracks 
Cracks radiating from rivet or staybolt holes 
may be repaired if the plate is not seriously 
damaged. If the plate is seriously damaged, 
it shall be replaced. For suggested methods 
of repair, (see Figure 3.3.4.2-b). 

Minor Defects 

Minor cracks, isolated pits, and small plate 
imperfections should be examined to deter- 
mine the extent of the defect and whether 
repair by welding is required. Prior to repair 
by welding, the defects shall be removed to 
sound metal. Liquid penetrant or magnetic 
particle examination may be used before or 
after welding. 

Defective Bolting 

Defective bolting material shall not be re- 
paired but shall be replaced with suitable 
material that meets the specifications of the 
original code of construction. 



FIGURE 3.3.4.2-a 
Unstayed Boiler Furnaces 




Cracks at the knuckle or at the turn of the furnace opening require immediate 
replacement of the affected area. If repairs arc attempted, specific approval of 
the jurisdiction is required. 



64 



NATIONAL BOARD INSPECTION CODE • PART 3 



REPAIRS AND ALTERATIONS 



f) Bulges 



A bulge on a watertube shall be investi- 
gated to determine the cause and extent 
of damage to the tube prior to repair. If 
the bulge has resulted in metallurgical 
changes to the original tube material, 
as determined by field metallography, 
installation of a new length of tubing or 
lube patch (sec; 3.3.4.6|b|) is required. 
If the bulge has cracks as determined 
by NDE, installation of a new length of 
tubing or a tube patch is required. If the 
bulge does not exhibit cracks and has 
not resulted in metallurgical changes to 
the original tube material, a mechani- 
cal repair may be considered subject 
to the concurrence of the Inspector or 
Jurisdiction. 



2) A bulge on a plate shall be investigated 
to determine the cause and extent of 
damage to the plate prior to repair. If 
the bulge has resulted in metallurgical 
changes to the original plate material, 
as determined by field metallogra- 
phy, installation of a flush patch (see 
3.3.4. 6[a]) is required. If the plate has 
cracks as determined by NDE, installa- 
tion of a flush patch is required. If the 
bulge does not exhibit cracks and has 
not resulted in metallurgical changes to 
the original plate material, a mechani- 
cal repair may be considered, subject 
to the concurrence of the Inspector or 
Jurisdiction. 



FIGURE 3.3.4.2-b 

Rivet and Staybolt Hole Cracks 

Cracks radiating from rivet or staybolt holes should be repaired if the plate is not seriously damaged. If the plate is 
seriously damaged, it shall be replaced. A suggested repair method is described below: 

a. Prior to welding, the rivets or staybolts from which the cracks extend and the adjacent rivets (or staybolts if ap- 
propriate) should be removed. 

b. In riveted joints, tack bolts should be placed in alternate holes to hold the plate laps firmly. 

c. The cracks should then be prepared for welding by chipping, grinding, or gouging. 

d. In riveted joints, cracks which extend past the inner edge of the plate lap should be welded from both sides. 

e. Rivet holes should be reamed before new rivets are driven. 

f. Threaded staybolt holes should be relapped and new staybolts properly driven and headed. 





Circumferential Cracks at Girth Sear 



Fire Cracks at Girth Seams 





© 



Q 



Fire Cracks at Door Openings 



Cracks in Stayed Plates 



65 



NATIONAL BOARD INSPECTION CODE • PART 3 



REPAIRS AND ALTERATIONS 



g) Blisters 

A blister may be caused by a defect in the 
metal such as lamination where one side 
exposed to the tire overheats but the other 
side retains its strength due to the cooling 
effect of the water. After the blistered mate- 
rial has been removed, the remaining wall 
thickness shall be determined by ultrasonic 
thickness testing. A surface examination 
using liquid penetrant testing or magnetic 
particle testing shall be made to assure the 
remaining material contains no defects. If 
the remaining wall thickness is adequate, 
in the judgment of the Inspector, the area 
may be repaired by welding as covered 
in 3.3.4.3, Wasted Areas. If the remaining 
wall thickness is not adequate, a plate will 
require a flush patch (See 3.3.4.G[a]) and 
a tube will require a new length of tube or 
tube patch (see 3.3.4.6[b|). 



3.3.4.3 WASTED AREAS 



ing up with weld metal, provided that metal 
removed in the process does not reduce the 
thickness of the flange to a measurement 
below that calculated above. Flanges that 
leak because of warpage or distortion and 
which cannot be re-machined shall be re- 
placed with new flanges that have at least 
the dimensions conforming to the original 
code of construction. 

d) Tubes 

Wasted areas on tubes may be repaired by 
welding provided that in the judgment of 
the Inspector the strength of the lube has 
not been impaired. Where deemed neces- 
sary, competent technical advice should 
be obtained from the manufacturer or from 
another qualified source. This may be nec- 
essary when considering such items as size 
limitations of repaired areas, minimum lube 
thickness to be repaired, tube environment, 
location of the tube in the boiler, and other 
similar conditions. 



a) Shells, Drums, Headers 

Wasted areas in stayed and unstayed shells, 
drums, and headers may be built up by 
welding provided that in the judgment of 
the Inspector the strength of the structure 
has not been impaired. Where extensive 
weld buildup is employed, the Inspector 
may require an appropriate method of NDE 
for the completed surface of the repair. For 
suggested methods of building up wasted 
areas by welding. (See Figure 3.3.4.3-a). 

b) Access Opening 

Wasted areas around access openings may 
be built up by welding or they may be re- 
paired as described in Figure 3.3.4.3-b. 

c) Flanges 

Wasted flange faces may be cleaned thor- 
oughly and built up with weld metal. They 
should be machined in place, if possible, to 
a thickness not less than that of the original 
flange or that required by calculations in ac- 
cordance with the provisions of the original 
code of construction. Wasted flanges may 
also be re-machined in place without build- 



e) External Weld Metal Buildup 



A07 



1) Pressure-retaining items that have local- A08 
ized internal thinning due to erosion 
and/or corrosion and where the internal A08 
surface is not readily accessible may be 
weld repaired by depositing weld metal 

on the external surface of the item as 
shown in Figure 3. 3. 4. 3-c. This method A08 
of repair is subject to approval by the 
Inspector and the Jurisdiction, where 
required. 

2) All of the following conditions shall A07 
apply for this repair method to be per- 
mitted: 

a. The component to be repaired shall A07 
be a ferrous material. A08 

b. The maximum design temperature A07 
of the repaired component shall 

not exceed 650°F (340°C), and the 
minimum design temperature shall 
not be less than -20°F (-29°C). 

c. The pressure-retaining item shall be A07 



66 



NATIONAL BOARD INSPECTION CODE • PART 3 



REPAIRS AND ALTERATIONS 



A07 



A07 



A08 



A07 



A07 



volumetrically examined for cracks 
in the area to be weld repaired. 
If cracks are dcleclcd, this repair 
method shall NOT be used. 

The WPS followed shall be quali- 
fied for weld metal buildup in 
accordance with ASME Section 
IX. The nominal chemical analysis 
of the deposited weld metal shall 
be equivalent to the base material 
that is to be repaired. In addition, 
the nominal tensile strength of the 
deposited weld metal shall be equal 
to or exceed the specified minimum 
tensile strength and shall be based 
on the requirements of the welding 
consumable. If butt joints in the 
component being overlaid required 
postweld heat treatment (PVVHT) by 
the code of construction, the WPS 
followed for the weld buildup shall 
be given PWHT. 

The pressure-retaining item shall be 
taken out of service prior perform- 
ing the weld metal buildup. The 
owner of the pressure-retaining 
item shall evaluate the flammabil- 
ity, volatility, or potential reaction of 
the contents that were in the vessel 
to ensure safe working conditions 
during weld repair. When required 
by the results of this evaluation, the 
pressure-retaining item shall be 
drained of its contents to the extent 
necessary to make the repair. 

This method may be used more 
than once in the same areas to 
repair locally thinned areas; how- 
ever , the cumulative weld buildup 
for all repairs shall not exceed the 
thickness (t) of the component at 
any point. 

Repairs using this method shall 
not cover more than 25% of the 
circumference of the component. 



A07 3) External weld buildup shall be applied 



in accordance with the following re- 
quirements: 

a. The area to be repaired shall be 
ultrasonically scanned for wall 
thickness, and the location and 
size of the thinned region shall be 
mapped. 

b. The area requiring repairs and the A07 
boundaries of the weld buildup 
shall be marked on the external 
surface of the component. 

c. The general design of the external 
weld buildup shall be in accor- 
dance with Figure 3.3.4.3-c. The 
finished weld buildup shall be 
circular, oval, or rectangular in 
shape. 

d. The weld buildup shall extend, at A07 
full thickness, a minimum distance 

B in each direction beyond the 
boundaries of the thinned base 
metal area. 

1. B = 3/4\ ; Rt 

nom 

2. R = outer radius of the com- 
ponent, or D/2 

3. t = nominal wall thickness 

nom 

or the component 

The thickness shall be sufficient 
to maintain the predicted life of 
the repair. Any corrosion allow- 
ance that is determined to be 
necessary shall be added to the 
value of B. 

e. All edges of the weld buildup shall be A07 
tapered to the existing contour of the com- 
ponent, at a maximum angle (a) of 45°. 

f. The thickness of the weld buildup shall A07 
be uniform except along tapered edges as 
welded surfaces are acceptable provided 
they are free of coarse ridges and valleys 
and are suitable for any required nonde- 
structive examinations. 



&v 



NATIONAL BOARD INSPECTION CODE • PART 3 — REPAIRS AND ALTERATIONS 



FIGURE 3.3.4.3-a 

Weld Buildup of Wasted Area 

Rivet and Staybolts 

a. Prior to welding the rivets or staybolts in the wasted area should be removed. 

b. Threaded staybolt holes should be retapped after welding. 

c. Rivet holes should be reamed after welding. 

d. Welding should not cover rivet or staybolt heads. 




Tubesheet 

a. Prior to welding the tubes in the wasted area should be removed. 

b. After welding the tube holes may be reamed before new tubes are installed. 




Wasted areas in stayed and unstayed surfaces may be repaired by weld buildup, provided that in the judgment of 
the inspector ihe strength of the structure will not be impaired. Where extensive weld buildup is employed, the 
inspector may require an appropriate method of NDE for the complete surface of the repair. 



6B 



NATIONAL BOARD INSPECTION CODE • PART 3 — REPAIRS AND ALTERATIONS 



FIGURE 3.3.4.3-b 

Repairs for Access Openings 

A badly wasted manhole flange may be removed and replaced with a ring-type frame as shown below. The 
requirements for flush patches shall be met. A full penetration weld is required. May be either double or welded 
from one side with or without a backing ring. 




^ 1 ) ) I F r 



^- Backing Ring 

3 



Pressure Side 



A badly wasted area around a handhole opening may be repaired by adding a ring, as shown below, on the 
inside of the object. 



Wasted area removed 




v ; y^ ,/- Orifl i n at edge of opening 
w,v Ring 



t n . ' ' T 

Pressure Side 



Minimum lap 
% in. (12.7 mm) 



A07 FIGURE 3.3.4.3-c 

External Overlay Terms and Definitions 

t 




W B ... LorC 

f * 1 ^B fl fr ' l rf ml ■ 

.W.....J — „j_ 



a 




L = length of area to be repaired along the 
axis of the component 

C = length of area to be repaired along out- 
side circumference of the component 

W =fhe completed thickness of the overlay 

a - the angle between the component and 
the overlay (maximum 45°) 

B - 3/4 \'(R t) minimum 

R = nominal outside radius of the compo- 
nent 

D = the nominal outside diameter of the 
component 

t - nominal wall thickness of the 
component 

u = remaining wall thickness of the 
component shall be 1/1 6 or greater 



69 



NATIONAL BOARD INSPECTION CODE • PART 3 



REPAIRS AND ALTERATIONS 



A07 g- All corners of the weld buildup shall have 
a minimum radius (r), not less than the 
overlay thickness. 

A07 h. Any corrosion allowance that is determined 
to be necessary shall be added to the thick- 
ness of the weld buildup. 

A07 i- The thickness (W) of the weld deposit plus 
the remaining wall thickness in the affected 
area (u) of the component at it thinnest 
point shall not exceed the nominal wall 
thickness (t) of the component. This shall 
be verified by ultrasonic methods. 

A07 j- Final dimension and contour of the weld 
buildup may be achieved by grinding or 
machining. This work may be done before 
or after any PWHT. 

A07 k. The weld buildup shall be examined by 
liquid penetrant inspection or wet fluores- 
cent magnetic particle inspection. If the 
butt welds in the component being built 
up were required to be volumetrically ex- 
amined during the original construction, 



the built-up area shall be similarly volu- 
metrically examined. 

I. For each repair, the maximum dimension A07 
(L, length along axis) compensated by a 
circular or oval weld buildup shall not ex- 
ceed the lesser of 1/4 the nominal outside 
diameter or the component of 8 in. (200 
mm). The length of a rectangular patch is 
not limited. 

m. The distance between the weld toes of the A07 
multiple weld buildup regions on a com- 
ponent outer diameter surface area shall 
not be less than 3/4 \'(Rt). 



3.3.4.4 



SEAL WELDING 



Seal Welding of Tubes 
Tubes may be seal welded, provided the 
ends of the tubes have sufficient wall 
thickness to prevent burn-through and the 
requirements of the original code of con- 
struction arc satisfied as shown in Figure 
3.3.4.4-a. 



FIGURE 3.3.4.4-a 

Typical Examples of Seal Welding Tubes 

Tubes may be seal welded provided the ends of the tubes have sufficient wall thickness to prevent burn-through. 
Seal welding shall be applied in strict accordance with the original code of construction for the requirements of 
the tube projection, welding, and tube expanding. Seal welding shall not be considered a strength weld. 

In watertube boilers, tubes may be seal welded on the inside or outside of the tubesheet. 



M 



LJ F 



ST 



ft 



I 






7 ~V 



3 




7D 



NATIONAL BOARD INSPECTION CODE • PART 3 



REPAIRS AND ALTERATIONS 



b) Seal Welding of Riveted Joints 

Edges of buttstraps, plate laps, and nozzles, 
or of connections attached by riveting 
may be restored to original dimensions 
by welding. Seal welding of riveted joints, 
buttstraps, or rivets shall require the ap- 
proval of the Jurisdiction. If seal welding is 
approved, suggested methods and precau- 
tions are shown in Figure 3.3.4.4-b. 



3.3.4.5 RE-ENDING OR PIECING PIPES 
OR TUBES 

Re-ending or piecing pipes or tubes is permit- 
ted provided the thickness of the remaining 
pipe or tube is not less the minimum thickness A07 
required by the original code of construction. 

(See Figure 3.3.4.5). 



FIGURE 3.3.4.4-b 

Seal Welding of Riveted Joints 

Seal welding of riveted joints requires the approval of the Jurisdiction. Seal welding shall not be considered a 
strength weld. Prior to welding, the area should be examined by an appropriate method of NDE to ensure that 
there are no cracks radiating from the rivet holes. If necessary, the rivets should be removed to ensure complete 
examination of the area. Seal welding should not be performed if cracks are present in riveted areas. 



Throat approx. 1/8 in. (3.2 mm) 



Typical Rivet Joint Showing Seal Weld 




FIGURE 3.3.4.5 

Re-Ending or Piecing of Pipes or Tubes 





re-ending 



piecing 



A07 



7 1 



NATIONAL BOARD INSPECTION CODE • PART 3 



REPAIRS AND ALTERATIONS 



3.3.4.6 



PATCHES 



a) Flush Patches 

1) The weld around a flush patch shall 
be a full penetration weld and the 
accessible surfaces shall be ground 
flush where required by the applicable 
original code of construction. Examples 
of flush welded patches arc shown in 
Figure 3.3.4.6-a. The welds shall be 
subjected to the nondestructive ex- 
amination method used in the original 
code of construction or an alternative 
acceptable to the Inspector. 

2) Before installing a flush patch, the 
defective material should be removed 
until sound material is reached. The 
patch should be rolled to the proper 



b) 



shape or curvature. The edges should 
align without overlap. In stayed areas, 
the weld seams should come between 
staybolt rows or riveted seams. Patches 
shall be made from a material whose 
composition and thickness meet the 
intended service. Patches may be any 
shape or size. If the patch is rectangular, 
an adequate radius should be provided 
at the corners. Square corners should 
be avoided. The completed welds shall 
meet the requirements of the original 
code of construction. 

Tube Patches 

In some situations it is necessary to weld a 
flush patch on a tube, such as when replac- 
ing tube sections and accessibility around 
the complete circumference of the tube is 
restricted, or when it is necessary to repair 



A07 



FIGURE 3.3.4.6-a 

Flush Patch Configurations in Unstayed Areas 




, f ,.„ 









A07 



Flush Patches in Stayed Areas 



A07 




72 



NATIONAL BOARD INSPECTION CODE • PART 3 — REPAIRS AND ALTERATIONS 



coverings that may inhibit or compromise a 
meaningful pressure test shall be removed, 
to the extent identified by the Inspector. 

A07 e) In lieu of pressure testing, alternative meth- 
ods can be used to ensure the structural 
integrity of the re-rated pressure-retaining 
item. The alternative methods shall be 
documented and subject to review and 
approval by the Jurisdiction. 



3.4.2 ALTERATIONS BASED ON 

ALLOWABLE STRESS VALUES 

A07 For re-rating or re-calculating a new minimum 
wall thickness for a pressure-retaining item 
using a later edition/addenda of the original 
code of construction or selected construction 
standard or code that permits use of higher al- 
lowable material stress values than were used 
in the original construction, the following re- 
quirements shall apply: 

a) The "R" Certificate Holder shall verify, by 
calculations and other means, that the re- 
rated item can be satisfactorily operated at 
the new service condition (e.g., stiffness, 
buckling, external mechanical loadings). 

b) The pressure-retaining item shall not be 
used in lethal service. 

c) The pressure-retaining item shall not be 
used in high-cycle operation or fatigue 
service (i.e., loadings other than primary 
membrane stress are controlling design 
considerations) unless the pressure-re- 
taining item was originally designed for 
fatigue service and a fatigue analysis is 
performed. 

d) The pressure-retaining item shall have been 
constructed to the 1968 edition or later 
edition/addenda of the original code of 
construction. 

e) The pressure-retaining item shall be shown 
to comply with all relevant requirements 
of the edition/addenda of the code of 



construction, which permits the higher al- 
lowable stress values (e.g., reinforcement, 
toughness, examination, pressure testing). 

f) The pressure-retaining item shall have a 
satisfactory operating history and current 
inspection of the pressure-retaining item 
shall verify the item exhibits no unrepaired 
damage (e.g., cracks, corrosion, erosion). 
Areas of corrosion or erosion may be left 
in place provided the remaining wall thick- 
ness is greater than the minimum thickness 
for the new design conditions. 

g) The re-rating shall be acceptable to the 
Inspector and, where required, the Jurisdic- 
tion. 

h) All other requirements of Part 3, as appli- 
cable, and jurisdictional requirements shall 
be met. 

i) Use of this paragraph shall be documented 
in the "Remarks" section of Form R-2. 



3.4.3 



EXAMPLES OF ALTERATIONS 



a) An increase in the maximum allowable 
working pressure (internal or external) or 
temperature of a pressure-retaining item 
regardless of whether or not a physical 
change was made to the pressure-retaining 
item; 

b) A decrease in the minimum temperature; 

c) The addition of new nozzles or openings 
in a boiler or pressure vessel except those 
classified as repairs; 

d) A change in the dimensions or contour of 
a pressure-retaining item; 

e) In a boiler, an increase in the heating surface 
or steaming capacity such that an increase 
in the relieving capacity is required; 

f) The addition of a pressurized jacket to a 
pressure vessel; 



75 



NATIDNAL BOARD INSPECTION CODE • PART 3 — REPAIRS AND ALTERATIONS 



g) Except as permitted in 3.3.3 s), replacement 
of a pressure-retaining part in a pressure- 
retaining item with a material of different 
allowable stress or nominal composition 
from that used in the original design; and 

h) The addition of a bracket or an increase in 
loading on an existing bracket that affects 
the design of the pressure-retaining item to 
which it is attached. 



3.4.4 



3.4.4.1 



ALTERATION OF ASME CODE 
SECTION VHS, DIVISION 2 OR 
3, PRESSURE VESSELS 



ALTERATION PLAN 



a) Professional Engineer Review 

The alteration plan shall be reviewed and 
certified by a Professional Engineer who is 
registered in one or more of the states of 
the United States of America or the prov- 
inces of Canada, is experienced in pressure 
vessel design, and is knowledgeable in 
ASME Section VIM, Division 2 or 3, as ap- 
plicable. The review and certification shall 
be such as to ensure the work involved in 
the alteration is compatible with the user's 
design specification and the Manufacturer's 
Design Report. 

b) User's Design Specification 

If the alteration is such that the work is not 
compatible with or changes one or more 
requirement(s) of the original user's design 
specification, the user's design specifica- 
tion shall be revised by the user with the 
new parameters or changes. The revisions 
shall be certified by a Professional Engineer 
who is registered in one or more of the 
states of the United States of America or 
the provinces of Canada, is experienced in 
pressure vessel design, and is knowledge- 
able in ASME Section VIII, Division 2 or 3, 
as applicable. 



d) 



Manufacturer's Design Report 
The "R" Certificate Holder shall prepare or 
cause to have prepared a supplement to the 
manufacturer's design report to reconcile 
the new parameters or changes with the 
user's design specification. 

The supplement to the manufacturer's 
design report shall be certified by a Profes- 
sional Engineer who is registered in one 
or more of the states of the United States 
of America or the provinces of Canada, is 
experienced in pressure vessel design, and 
is knowledgeable in ASME Section VIII, 
Division 2 or 3, as applicable. 

Authorized Inspection Agency Acceptance 
Following review and certification, the 
alteration plan shall be submitted for accep- 
tance to the Authorized Inspection Agency/ 
Owner-User Inspection Organization 
whose inspector will make the acceptance 
inspection and sign the Form R-2. 



76 




Part 3, Section 4 
Repairs and Alterations 
Examination and Testing 



77 



NATIONAL BOARD INSPECTION CODE • PART 3 



REPAIRS AND ALTERATIONS 



PART 3, SECTION 4 
REPAIRS AND ALTERATIONS — EXAMINATION AND TESTING 



A07 4.1 



SCOPE 



This section provides requirements and guide- 
lines for performing examinations and tests for 
repairs and alterations to pressure-retaining 
items. 



4.2 NONDESTRUCTIVE 

EXAMINATION 

a) The nondestructive examination (NDE) 
requirements, including technique, extent 
of coverage, procedures, personnel quali- 
fication, and acceptance criteria, shall be 
in accordance with the original code of 
construction for the pressure-retaining item. 
Weld repairs and alterations shall be sub- 
jected to the same nondestructive exami- 
nation requirements as the original welds. 
Where this is not possible or practicable, 
alternative NDE methods acceptable to the 
Inspector and the Jurisdiction where the 
pressure-retaining item is installed, where 
required, may be used. 

b) NDE personnel shall be qualified and certi- 
fied in accordance with the requirements 
of the original code of construction. When 
this is not. possible or practicable, NDE 
personnel may be qualified and certified 
in accordance with their employer's written 
practice. ASNT SNT-TC-1 A, Recommended 
Practice Nondestructive Testing Personnel 
Qualification and Certification (2001 edi- 
tion), or ASNT CP-1 89, Standard for Quali- 
fication and Certification of Nondestructive 
Testing Personnel (2001 edition), shall be 
used as a guideline for employers to estab- 
lish theirwritten practice. The ASNT Central 
Certification Program (ACCP, Rev. 3, Nov. 
1997) may be used to fulfill the examina- 
tion and demonstration requirements of 
the employer's written practice. Provisions 



for training, experience, qualification, and 
certification of NDE personnel shall be 
described in the "R" Certificate Holder's 
written quality system. 



4.3 PRESSURE GAGES, 

MEASUREMENT, EXAMINATION, 
AND TEST EQUIPMENT 

The calibration of pressure gages, measure- 
ment, examination, and test equipment, and 
documentation of calibration shall be per- 
formed as required by the applicable standard 
used for construction. 



4.4 EXAMINATION AND TEST FOR 

REPAIRS AND ALTERATIONS 



A07 



The following requirements shall apply to all 
repairs and alterations to pressure-retaining 
items: 

a) The integrity of repairs, alterations, and 
replacement parts used in repairs and al- 
terations shall be verified by examination 
or test. 

b) Testing methods used shall be suitable for 
providing meaningful results to verify the 
integrity of the repair or alteration. Any 
insulation, coatings, or coverings that may 
inhibit or compromise a meaningful test 
method shall be removed, to the extent 
identified by the Inspector. 

c) The "R" Certificate Holder is responsible 
for all activities relating to examination and 
test of repairs and alterations. 

d) Examinations and tests to be used shall be 
subject to acceptance of the Inspector and, 
where required, acceptance of the Jurisdic- 
tion. 



78 



NATIONAL BOARD INSPECTION CODE ♦ PART 3 — REPAIRS AND ALTERATIONS 



4.4.1 TEST OR EXAMINATION 

METHODS APPLICABLE TO 
REPAIRS 

Based on the nature and scope of the repair 
activity, one or a combination of the follow- 
ing examination and test methods shall be 
applied to repairs and replacement parts used 
in repairs. 

a) Liquid Pressure Test 

Pressure testing of repairs shall meet the 
following requirements: 

1) Pressure tests shall be conducted us- 
ing water or other liquid medium. The 
test pressure shall be the minimum 
required to verify the leak tightness 
integrity of the repair, but not more 
than 150% of the maximum allowable 
working pressure (MAWP) stamped 
on the pressure-retaining items, as ad- 
justed for temperature. When original 
test pressure included consideration of 
corrosion allowance, the test pressure 
may be further adjusted based on the 
remaining corrosion allowance. 

2) During a pressure test where the test 
pressure will exceed 90% of the set 
pressure of the pressure relief device, 
the device shall be removed whenever 
possible. If not possible, a spindle re- 

A07 straint may be used following the valve 

manufacturer's instructions and recom- 
mendations. Extreme caution should be 
employed to ensure only enough force 
is applied to contain pressure. Excessive 

A07 mechanical force applied to the spindle 

restraint may result in damage to the 
seat and/or spindle and may interfere 
with the proper operation of the valve. 

A07 The spindle restraint shall be removed 

following the test. 

The organization who performs the 
pressure test and applies a spindle 
restraint shall attach a metal tag that 



b) 



identifies the organization and date 
the work was performed to the pres- 
sure relieving device. If the seal was 
broken, the organization shall reseal 
the adjustment housing with a seal that 
identifies the responsible organization. 
The process shall be acceptable to the 
Jurisdiction where the pressure-retain- 
ing items are installed. 

3) The metal temperature for the pressure 
test shall be in accordance with the 
original code of construction, but not 
less than 60°F (1 6°Q unless the owner 
provides information on the tough- 
ness characteristics of the material to 
indicate the acceptability of a lower 
test temperature. During close exami- 
nation the metal temperature shall not 
exceed 1 20 C F (49°C), unless the owner 
specified requirements for a higher test 
temperature, and it is acceptable to the 
Inspector. 

4) Hold-time for the pressure test shall be 
a minimum of 10 minutes prior to ex- 
amination by the Inspector. Where the 
test pressure exceeds the MAWP of the 
item, the test pressure shall be reduced 
to the MAWP for close examination by 
the Inspector. Hold-time for close ex- 
amination shall be as necessary for the 
Inspector to conduct the examination. 

Pneumatic Test 

A pneumatic test may be conducted. Con- 
currence of the owner shall be obtained in 
addition to that of the Inspector and Juris- 
diction where required. The test pressure 
shall be the minimum required to verify 
leak tightness integrity of the repair, but 
shall not exceed the maximum pneumatic 
test pressure of the original code of con- 
struction. Precautionary requirements of 
the original code of construction shall be 
followed. 



79 



NATIONAL BOARD INSPECTION CODE • PART 3 



REPAIRS AND ALTERATIONS 



c) Initial Service Leak Test 

When an initial service leak test is permitted 
by the original code of construction, such 
testing may also be used to verify the leak 
tightness integrity of repairs. 

d) Vacuum Test 

A vacuum test may be conducted. Vacuum 
test methods used shall be suitable to verify 
the leak tightness integrity of the repair. 

e) Nondestructive Examination (NDE) 

NDE may be conducted. Exclusive use of 
Visual Examination (VT) shall not be permit- 
ted. NDE methods used shall be suitable for 
providing meaningful results to verify the 
integrity of the repair. 



4.4.2 TEST OR EXAMINATION 

METHODS APPLICABLE TO 
ALTERATIONS 

Based on the nature and scope of the alterations 
activity, one or a combination of the following 
examination and test methods shall be applied 
to alterations and replacement parts used in 
alterations. 

a) liquid Pressure Test 

Pressure testing of alterations shall meet the 
following requirements: 

1) A pressure test as required by the 
original code of construction shall 
be conducted. The test pressure shall 
not exceed 150% of the maximum 
allowable working pressure (MAWP) 
stamped on the pressure-retaining item, 
as adjusted for temperature. When the 
original test pressure included consid- 
eration of corrosion allowance, the test 
pressure may be further adjusted based 
on the remaining corrosion allowance. 
The pressure test for replacement parts 
may be performed at the point of manu- 
facture or point of installation. 

2) As an alternative to pressure testing 
connecting welds in accordance with 



the original code of construction, con- 
necting welds may be tested or exam- 
ined in accordance with the rules for 
repairs (see 4.4.1). Connecting welds 
are defined as welds attaching the re- 
placement part to the pressure-retaining 
item. 

3) During a pressure test where the test 
pressure will exceed 90% of the set 
pressure of the pressure relief device, 
the device shall be removed whenever 
possible. If not possible, a spindle re- A07 
straint may be used following the valve 
manufacturer's instructions and recom- 
mendations. Extreme caution should be 
employed to ensure only enough force 

is applied to contain pressure. Excessive 
mechanical force applied to the spindle 
restraint may result in damage to the 
seat and/or spindle and may interfere 
with the proper operation of the valve. 
The spindle restraint shall be removed 
following the test. 

a. The organization who performs the 
pressure test and applies a spindle 
restraint shall attach a metal tag 
that identifies the organization and 
date the work was performed to the 
pressure relieving device. If the seal 
was broken, the organization shall 
reseal the adjustment housing with 
a seal that identifies the responsible 
organization. The process shall be 
acceptable to the Jurisdiction where 
the pressure-retaining items are 
installed. 

4) The metal temperature for the pressure 
test shall be in accordance with the 
original code of construction, but not 
less than 60°F (1 6°C), unless the owner 
provides information on the tough- 
ness characteristics of the material to 
indicate the acceptability of a lower 
test temperature. During close exami- 
nation the metal temperature shall not 
exceed 1 20°F (49°C), unless the owner 



so 



NATIONAL BOARD INSPECTION CODE • PART 3 — REPAIRS AND ALTERATIONS 



specifies requirements for a higher test 
temperature and it is acceptable to the 
Inspector. 

5) Hold-time for the pressure test shall be a 
minimum of 10 minutes prior to exami- 
nation by the Inspector. The test pressure 
shall be reduced to the MAWP for close 
examination by the Inspector. 

a. Hold-time for close examination 
shall be as necessary for the Inspec- 
tor to conduct the examination. 

b) Pneumatic Test 

A pneumatic test may be conducted when 
contamination of the pressure-retaining item 
by liquids is possible or when liquid pres- 
sure testing is not practicable. Concurrence 
of the owner shall be obtained in addition 
to the Inspector and Jurisdiction where 
required. Pneumatic test requirements and 
precautions shall be in accordance with the 
original code of construction. 

c) Nondestructive Examination 

NDE may be conducted when contami- 
nation of the pressure-retaining item by 
liquids is possible or when pressure test- 
ing is not practicable. Concurrence of the 
owner shall be obtained in addition to the 
Inspector and Jurisdiction where required. 
A08 Exclusive use of Visual Examination (VT) 
shall not be permitted. In all cases NDE 
methods or combination of methods used 
shall be suitable for providing meaningful 
results to verify the integrity of the altera- 
tion. 



4.5.1 TEST MEDIUM AND TESTING 

EQUIPMENT 

Valves marked for steam service, or having 
special internal parts for steam service, shall 
be tested on steam. Valves marked for air, gas, 
or vapor service shall be tested with air or gas. 
Valves marked for liquid service shall be tested 
with water or other suitable liquid. ASME Code, 
Section IV hot-water valves shall be tested on 
water, steam, or air. 

a) Each valve shall be tested to demonstrate 
the following: 

1) Set pressure (as defined by the valve 
manufacturer and as listed in NB-18, 
Pressure Relief Device Certifications) 

2) Response to blowdown, when required 
by the original code of construction; 

3) Seat lightness; and 

4) For valves designed to discharge to a 
closed system, the tightness of the sec- 
ondary pressure zone shall be tested 
as required by the original code of 
construction. 

b) The equipment used for the performance 
testing prescribed by Section 4.5.1 shall 
meet the following requirements: 

I) The performance testing equipment 
shall include a pressure vessel of ad- 
equate volume and pressure source 
capacity to ensure compliance with 
4.5.1a)1). 



4.5 PRESSURE RELIEF VALVE 

PERFORMANCE TESTING AND 
TESTING EQUIPMENT 

Each pressure relief valve to which the "VR" 
repair symbol stamp is to be applied shall be 
subjected to the following tests by the repair 
certificate holder. 



2) Prior to use, all performance testing 
equipment shall be qualified by the 
Certificate Holder to ensure that the 
equipment and testing procedures will 
provide accurate results when used 
within the ranges established for that 
equipment. This qualification may be 
accomplished by benchmark testing, 
comparisons to equipment used for 



B 1 



NATIONAL BOARD INSPECTION CODE • PART 3 



REPAIRS AND ALTERATIONS 



verification testing as specified in the 
quality system, or comparisons to field 
performance. This qualification shall be 
documented and provisions made to 
retain such documentation for a period 
of at least five years after the testing 
equipment is retired. Documentation 
of this qualification shall include but 
not be limited to: 

a. Schematic of the performance test 
equipment; 

b. Size and pressure ranges of valves 
to be tested and the test fluid to be 
used; 

c. Dimensions of test vessels; 

d. Accuracy of pressure measuring 
equipment; 

e. Size and design type of valves used 
to control flow; and 

f. Method of qualifying. 

Prior to the implementation of any 
addition or modification to the testing 
equipment that would a Iter the contents 
of the document required in 4.5.1(b)(2), 
the Certificate Holder shall re-qualify 
the performance test equipment in ac- 
cordance with 4.5.1 (b)(2). If the equip- 
ment changed was used to satisfy the 
requirements of verification testing, the 
Certificate Holder shall notify the Na- 
tional Board and additional verification 
testing, in accordance with the quality 
system, may be required. 



ment provided the valve manufacturer's cor- 
rections for differential in set pressure between 
steam and air are applied to the set pressure. 



4.5.3 



LIFT ASSIST TESTING 



a) A device may be used to apply an auxiliary 
lifting load on the spring of a repaired valve 
to establish the set pressure in lieu of the 
tests required in 4.5.1 a)1) when such testing 
at full pressure: 

1 ) may cause damage to the valve being 
tested; or 

2) is impractical when system design 
considerations preclude testing at full 
pressure. 

b) While actual valve blowdown and valve 
performance characteristics cannot be veri- 
fied, valve set pressure may be determined 
to an acceptable degree of accuracy using 
this testing technique provided, as a mini- 
mum, that: 

1) equipment utilized is calibrated as A07 
required in the quality system; 

2 ) the device and test procedures that have 
proved to give accurate results are used 
and followed; 

3) a static inlet pressure is applied with the 
test medium specified in 4.5.1 ; and 

4) adjustments are made in accordance 
with the valve manufacturer's recom- 
mendations to ensure proper lift and 
blowdown. 



4.5.2 OWNER-USER ASME CODE 

SECTION VIII STEAM TESTING 



4.5.4 



PRESSURE TEST OF PARTS 



When ASME Code Section VIII valves are re- 
paired by the owner for the owner's own use, 
valves for steam service may be tested on air for 
set pressure and, if possible, blowdown adjust- 



a) Parts used in repaired valves shall be pres- 
sure tested and documentation provided 
according to the following categories: 



sz 




Part 3, Section 5 

Repairs and Alterations — 

Certification/Documentation and 

Stamping 



as 



NATIONAL BOARD INSPECTION CODE • PART 3 



REPAIRS AND ALTERATIONS 



PART 3, SECTION 5 

REPAIRS AND ALTERATIONS — 

CERTIFICATION/DOCUMENTATION AND STAMPING 



A07 5.1 



SCOPE 



A07 This section provides requirements for certifica- 
tion, stamping, and documentation of repairs 
and alterations to pressure-retaining items. 
Applicable forms are provided in this section 
for reference. Forms may be obtained from the 
National Board Web site. 



5.2 DOCUMENTATION 

a) Repairs that have been performed in accor- 
dance with the NF3IC shall be documented 
on Form R-1 , Report of Repair, as shown 
in this section. Form R-4, Report Supple- 
mentary Sheet, shall be used to record 
additional data when space is insufficient 
on Form R-1 . 

b) Alterations performed in accordance with 
the NBIC shall be documented on Form 
R-2, Report of Alteration, as shown in this 
section. Form R-4, Report Supplementary 
Sheet, shall be used to record additional 
data when space is insufficient on Form 
R-2. 



5.2.1 PREPARATION OF FORM R-1 

(REPAIRS) 

a) Preparation of Form R-1 shall be the re- 
sponsibility of the "R" Certificate Holder 
performing the repair. 

b) An Inspector shall indicate acceptance by 
signing the Form R-1 . 

c) The Form R-3 and the Manufacturer's Data 
Reports described in this section shall be a 
part of the completed Form R-1 and shall 
be attached thereto. 



5.2.2 PREPARATION OF FORM R-2 

(ALTERATIONS) 

a) Initial preparation of Form R-2 shall be the 
responsibility of the "R" Certificate Holder 
responsible for the design portion of the 
alteration. The design organization shall 
complete and sign the "Design Certifica- 
tion" section of the Form R-2. An Inspector 
shall indicate acceptance of the design by 
signing the "Certificate of Design Change 
Review" section of the Form R-2. 

b) Final preparation of Form R-2, including 
the gathering and attaching of supporting 
reports, shall be the responsibility of the 
"R" Certificate Holder that performed the 
construction portion of the alteration. The 
construction organization shall complete 
the Form R-2 provided by the design orga- 
nization, including the "Construction Cer- 
tificate" section. An Inspector shall indicate 
that the work complies with the applicable 
requirements of this code by completing 
and signing the "Certificate of Inspection" 
section of the form. When no construction 
work is performed (e.g., a re-rating with 
no physical changes), the "R" Certificate 
Holder responsible for the design shall pre- 
pare the Form R-2, including the gathering 
and attaching of supporting reports. 

c) The following shall be attached to and be- 
come a part of the completed Form R-2: 

1 ) For ASME boilers and pressure vessels, 
a copy of the original Manufacturer's 
Data Report, when available; 

2) Form R-3, Report of Fabricated Parts 
or Manufacturer's Partial Data Reports; 
and 



SG 



NATIONAL BOARD INSPECTION CODE • PART 3 



REPAIRS AND ALTERATIONS 



For other than ASME, the manufactur- 
er's reports (i.e., reports required by 
the original code of construction, etc.), 
when available. 



5.3 DISTRIBUTION OF FORM R-1 

a) Legible copies of the completed Form R-1 , 
together with attachments, shall be distrib- 
uted to the owner or user, the Inspector, the 
Jurisdiction, if required, and the Authorized 
Inspection Agency responsible for inservice 
inspection. 

b) Distribution of Form R-1 and attachments 
shall be the responsibility of the organiza- 
tion performing the repair. 



b) It should be noted that some Jurisdictions 
may require registration of repairs and al- 
terations with the National Board. 

c) For those "R" Forms not registered with 
the National Board, the organization per- 
forming repairs or alterations shall retain a 
copy of the "R" Form on file for a minimum 
period of five years. 



5.5.1 



REGISTRATION FOR REPAIRS 



Form R-1 may be registered with the National 
Board as noted above. 



5.5.2 REGISTRATION FOR 

ALTERATIONS 



5.4 DISTRIBUTION OF FORM R-2 

a) Distribution of the completed Form R-2 
shall be the responsibility of the "R" Cer- 
tificate Holder that performed the con- 
struction portion of the alteration. When 
no construction work is performed (e.g., 
a re-rating with no physical changes), the 
"R" Certificate Holder responsible for the 
design shall distribute the form. 

b) Legible copies of the completed Form R-2, 
together with attachments, shall be distrib- 
uted to the Inspector, the authorized inspec- 
tion agency responsible for the inservice 
inspection of the pressure-retaining item, 
the owner-user, the "R" Certificate Holder 
responsible for design, and the Jurisdiction, 
if required. 



a) If the pressure-retaining item is originally 
registered with the National Board, an 
original Form R-2 together with attach- 
ments shall be registered with the National 
Board. 

b) If the item was not registered with the 
National Board, one original Form R-2 to- 
gether with attachments may be registered 
with the National Board or retained as 
required by 5.5. 



5.5.3 REGISTRATION FOR FIBER- 

REINFORCED VESSELS 

Organizations performing repairs or alterations 
under an "R" stamp program shall register 
such repairs or alterations with the National 
Board. 



5.5 REGISTRATION OF "R" FORMS 

— GENERAL 

a) Organizations performing repairs or al- 
terations under an "R" stamp program may 
register such repairs or alterations with the 
National Board. 



5.5.4 REGISTRATION FOR NUCLEAR 

REPAIR/REPLACEMENT 
ACTIVITIES 

Organizations performing repair/replacement 
activities under the "NR" stamp program shall 
register forms with the National Board. 



S7 



NATIONAL BOARD INSPECTION CODE • PART 3 



REPAIRS AND ALTERATIONS 



5.5.5 REGISTRATION FOR GRAPHITE b) 

VESSELS 

Organizations performing repair/replacement 
activities under the "R" stamp program shall 
register such repairs or alterations with the 
National Board. 



Subject to the acceptance of the Jurisdic- 
tion and the concurrence of the Inspector, 
nameplates and stamping may not be re- 
quired for routine repairs (see 3.3.2). In all 
cases, the type and extent of repairs neces- 
sary shall be considered prior to waiving 
the requirement. 



5.6 



FORM "R" LOG 



The "R" Certificate Holder shall maintain a 
single, sequential log of "R" Form numbers as- 
signed for NBIC Report Forms (e.g., R-1, R-2, 
and R-3) that are registered with the National 
Board. 



A07 5.7 



A07 5.7.1 



STAMPING REQUIREMENTS 
FOR REPAIRS AND 

ALTERATIONS 



GENERAL 



A07 The stamping of or attaching of a nameplate 
to a pressure-retaining item shall. indicate that 
the work was performed in accordance with 
the requirements of this Code. Such stamping 
or attaching of a nameplate shall be done only 
with the knowledge and authorization of the In- 
spector. The "R" Certificate Holder responsible 
for the repair or the construction portion of the 
alteration shall apply the stamping. For a re- 
rating where no physical changes are made to 
the pressure-retaining item, the "R" Certificate 
Holder responsible for design shall apply the 
stamping. Required stamping and nameplate 
information is shown in 5.9.6. 



5.7.2 STAMPING REQUIREMENTS 

FOR REPAIRS 

a) Pressure-retaining items repaired in accor- 
dance with the NBIC shall be stamped as 
required by this section. 



5.7.3 STAMPING REQUIREMENTS 

FOR ALTERATIONS 

Pressure-retaining items altered in accordance 
with this code shall have a nameplate or stamp- 
ing applied adjacent to the original manufactur- 
er's stamping or nameplate in accordance with 
this section. For an alteration where physical 
changes are made to the pressure-retaining 
item, the "R" Certificate Holder responsible 
for the construction portion of the alteration 
shall apply the stamping or nameplate. For an 
alteration where no physical changes are made 
to the pressure-retaining item (e.g., a re-rating) 
the "R" Certificate Holder, assuming responsi- 
bility for the design, shall apply the stamping 
or nameplate. 



5.8 REMOVAL OF ORIGINAL 

STAMPING OR NAMEPLATE 

If it becomes necessary to remove the original 
stamping, the Inspector shall, subject to the 
approval of the Jurisdiction, witness the making 
of a facsimile of the stamping, the obliteration 
of the old stamping, and the transfer of the 
stamping to the new item. When the stamping 
is on a nameplate, the Inspector shall witness 
the transfer of the nameplate to the new loca- 
tion. Any relocation shall be described on the 
applicable NBIC "R" Form. The re-stamping or A07 
replacement of a code symbol stamp shall be 
performed only as permitted by the governing 
code of construction. 



BB 



NATIDNAL BOARD INSPECTION CODE • PART 3 



REPAIRS AND ALTERATIONS 



5.9 



5.9.1 



STAMPING REQUIREMENTS 
FOR PRESSURE RELIEF DEVICES 



NAMEPLATES 



Proper marking and identification of tested or 
repaired valves is critical to ensuring accep- 
tance during subsequent inspections, and also 
provide for traceability and identification of any 
changes made to the valve. All operations that 
require the valve's seals to be replaced shall 
be identified by a nameplate as described in 
5.9.2 or 5.9.4. 



5.9.2 



REPAIR NAMEPLATE 



When a pressure relief valve is repaired, a 
metal repair nameplate stamped with the in- 
formation required below shall be securely 

A07 attached to the valve adjacent to the original 
manufacturer's stamping or nameplate. If not 
mounted directly on the valve, the nameplate 
shall be securely attached so as not to interfere 
with valve operation and sealed in accordance 

A07 with the quality system. 

a) Prior to attachment of the repair nameplate, 
the previous repair nameplate, if appli- 
cable, shall be removed from the repaired 
valve. 

b) As a minimum, the information on the valve 
repair nameplate (see Figure 5.9.6-e) shall 
include: 

1) The name of the repair organization 
preceded by the words "repaired by"; 

2) The "VR" repair symbol stamp and the 
"VR" Certificate Number; 



6) Capacity and capacity units (if changed 
from original nameplate due to set pres- 
sure or service fluid change); 

7) Type/Model number (if changed from 
original nameplate by a conversion. See 
Supplement S7.2); and 

8) When an adjustment is made to correct 
for service conditions of superimposed 
back pressure and/or temperature or the 
differential between popping pressure 
between steam and air (see 4.5.2), the 
information on the valve repair name- 
plate shall include the: 

a. Cold Differential Test Pressure 
(CDTP), and 

b. Superimposed Back Pressure (BP) 
(only when applicable). 



5.9.3 CHANGES TO ORIGINAL 

PRESSURE RELIEF VALVE 
NAMEPLATE INFORMATION 

a) If the set pressure is changed, the set pres- 
sure, capacity, and blowdown, if applica- 
ble, on the original nameplate or stamping 
shall be marked out but left legible. The 
new capacity shall be based on that for 
which the valve was originally certified. 

b) If the service fluid is changed, the capacity, 
including units, on the original nameplate 
or stamping shall be marked out but left 
legible. The new capacity shall be based 
on that for which the valve was originally 
certified, or if a conversion has been made, 
as described in S7.2 on the capacity certi- 
fication for the valve as converted. 



3) Unique identifier (e.g., repair serial 
number, shop order number, etc.); 

4) Date of repair; 

5) Set pressure; 



c) If the Type/Model number is changed, the 
Type/Model number on the original name- 
plate shall be marked out but left legible. 

d) If the blowdown is changed, the blowdown 
on the original nameplate or stamping shall 



B9 



NATIONAL BOARD INSPECTION CODE • PART 3 — REPAIRS AND ALTERATIONS 



A07 



be marked out but left legible. The new 
blowdovvn may be based on the current 
ASME Code requirements. 

Incorrect information on the original man- 
ufacturer's nameplate shall be marked out 
but left legible. Corrected information shall 
be indicated on the repair nameplate and 
noted on the document as required by the 
quality system. 



5.9.4 



TEST ONLY NAMEPLATE 



a) Where a valve has been tested and adjusted, 
as permitted by S7.10.1, but not otherwise 
repaired, a "Test Only" nameplate shall be 
applied that contains the following informa- 
tion: 

1 ) Name of responsible organization; 

2) Date of rest; 

3) Set Pressure; and 

4) Identification, such as "Test Only." 

b) A "test only" nameplate is also recom- 
mended when periodic testing has been 
performed, even when no adjustments have 
been made, for the purpose of identifying 
the date the valve was tested. 

c) The existing repair nameplates, if appli- 
cable, shall not be removed during such 
testing. 



5.9.5 REPLACEMENT OF ILLEGIBLE 

OR MISSING NAMEPLATES 



stamped "duplicate." It shall contain all 
information that originally appeared on the 
nameplate or valve, as required by the ap- 
plicable section of the ASME Code, except 
the "V," "HV," or "UV" symbol and the Na- 
tional Board mark. The repair organization's 
nameplate, with the "VR" stamp and other 
required data specified in 5.9.2, will make 
the repairer responsible to the owner and 
the Jurisdiction that the information on the 
duplicate nameplate is correct. 

b) Missing Nameplates 

When the original valve nameplate is 
missing, the repair organization is not 
authorized to perform repairs to the valve 
under the "VR" program, unless positive 
identification can be made to that specific 
valve and verification that the valve was 
originally stamped with an ASME "V" or 
"UV" symbol or marked with an ASME 
"HV" symbol. Valves that can be positively 
identified will be equipped with a duplicate 
nameplate, as described in this section, in 
addition to the repairer's "VR"-stamped 
nameplate. The repairer's responsibilities 
for accurate data, as defined in 5.9.5(a) 
(Illegible Nameplates), shall apply. 

c) Marking of Original Code Stamp 

When a duplicate nameplate is affixed to 
a valve, as required by this section, it shall 
be marked "Sec. I," "Sec. IV," or "Sec. VIII," 
as applicable, to indicate the original ASME 
Code stamping. 



5.9.6 REQUIREMENTS FOR 

STAMPING AND NAMEPLATE 
INFORMATION 



Illegible Nameplates 

When the information on the original 
manufacturer's or assembler's nameplate 
or stamping is illegible, buttraceability can 
be confirmed, the nameplate or stamping 
will be augmented or replaced by a name- 
plate furnished by the "VR" stamp holder 



5.9.6.1 



SCOPE 



When a pressure-retaining item is repaired 
or altered, the Certificate Holder shall attach 
a nameplate or stamp the item, except when 
otherwise permitted by these rules. Similarly, 
when pressure relief devices are repaired, the 



9D 



NATIONAL BOARD INSPECTION CODE • PART 3 — REPAIRS AND ALTERATIONS 



attachment of a nameplate is required. The 
specific requirements for nameplates/stamping 
are described in this Part. Sec Figures 5.9.6-a 
thru 5.9.6-g. 



5.9.6.2 GENERAL REQUIREMENTS FOR 

STAMPING AND NAMEPLATES 

a) Required data shall be in characters of 
at least 5/32 in. (4 mm) high, except that 
characters for pressure relief valve repair 
nameplates may be smaller. Markings may 
be produced by casting, etching, emboss- 
ing, debossing, stamping, or engraving. 
The selected method shall not result in any 
harmful contamination of or sharp discon- 
tinuities to the pressure-retaining item. 

b) The National Board code symbols ("R," 
"VR," and "N'R") are to be stamped; do not 
emboss. 



5.9.6.3 ADDITIONAL STAMPING 

REQUIREMENTS FOR REPAIRS 

Stamping or nameplate shall be applied adja- 
cent to the original manufacturer's stamping or 
nameplate. A single repair nameplate or stamp- 
ing may be used for more than one repair to 
a pressure-retaining item provided it is carried 
out by the same Certificate Holder. The date 
of each repair, corresponding with the date on 
the associated Form R-'l, shall be stamped on 
the nameplate. 



5.9.6.4 ADDITIONAL STAMPING 
REQUIREMENTS FOR 
ALTERATIONS AND RE-RATINGS 

Stamping or nameplate shall be applied adja- 
cent to the original manufacturer's stamping 
or nameplate. 



c) Stamping directly on items, when used, 
shall be done with blunt-nose continuous 
or blunt-nose interrupted dot die stamps. 
If direct stamping would be detrimental to 
the item, required markings may appear on 
a nameplate affixed to the item. 

d) The Certificate Holder shall use its full name 
as shown on the Certificate of Automa- 
tion or an abbreviation acceptable to the 
National Board. 

e) The letters "RP" shall be stamped below the 
"R" symbol stamp to indicate organizations 
accredited for performing repairs or altera- 
tions to fiber-reinforced plastic items. 

f) The letter "G" shall be stamped below the 
"R" symbol stamp to indicate organizations 
accredited for performing repairs or altera- 
tions to graphite pressure equipment. 



5.9.6.5 ADDITIONAL STAMPING 

REQUIREMENTS FOR PARTS 

Stamping or nameplate shall be applied in a 
conspicuous location on the part. 



5.1 ALTERNATIVE MARKING AND 

STAMPING FOR GRAPHITE 
PRESSURE EQUIPMENT 

a) General Requirements 

1) This procedure may be used in lieu of 
the stamping and nameplate require- 
ments defined in this section. 

2) The required data as defined in this 
section shall be 5/32 in. (4 mm) high, 
minimum. 

3) The National Board code symbol ("R") 
shall be used to make the impression 
in the cement. 



s i 



NATIONAL BOARD INSPECTION CODE • PART 3 



REPAIRS AND ALTERATIONS 



b) Application of the "R" Code Symbol 

1) The graphite surface shall be clean and 
smooth. 



Note: The preceding methods can be 
applied jointly to identify the graphite 
part and to transfer the "R" stamp. 



2) Apply a thin coating of cement onto the 
Code part. The cement should have the 
consistency of toothpaste. 

3) Apply sufficient heat to the cement so 
that it begins to form a skin. 

4) Apply a coating of a thinned release 
agent, such as "ANTISEIZE," to the tip 
of the "R" stamp with a brush. 

5) Press the coated stamp all the way to the 
bottom of the cement and remove by 
pulling straight out before the cement 
hardens. 

6) Cure or heat the impression as re- 
quired. 

7) When cured, the part may be washed 
to remove any excess release agent. 

c) Application of characters directly to graphite 

1) Use a very thin template of a flexible 
material (stainless steel; flexible and 
easily cleaned). 

2) Place the template over a clean smooth 
surface. 

3) Hold the template securely and trowel 
over with approved cement to fill all of 
the template area. 

4) Carefully lift the template from the 
graphite part and examine the detail of 
the characters. 

5) If acceptable, cure the cement. 

6) If the characters are incorrect or dam- 
aged, wipe off the cement with a com- 
patible solvent and reapply. 



5.11 STAMPING FOR FIBER- 

REINFORCED VESSELS 

The attaching of a nameplate to a repaired or 
altered vessel or tank shall indicate that the 
work was performed in accordance with the 
requirements of this Code. The attachment of a 
nameplate shall be done only with the knowl- 
edge and authorization of the Inspector. The 
Certificate Holder responsible for the repair or 
alteration shall apply the stamping nameplate. 
Required stamping and nameplate information 
are shown in 5.9.6. 



5.11.1 REMOVAL OF ORIGINAL 

STAMPING OR NAMEPLATE 

If it becomes necessary to remove the original 
stamping, the Inspector shall, subject to the 
approval of the Jurisdiction, witness the making 
of a facsimile of the stamping, the obliteration 
of the old stamping, and the transfer of the 
stamping to the new item. When the stamping 
is on a nameplate, the Inspector shall witness 
the transfer of the nameplate to the new lo- 
cation. Any relocation shall be described on 
the applicable NBIC form. The restamping or A07 
replacement of a code symbol stamp shall be 
performed only as permitted by the governing 
code of construction. 



5.11.2 



STAMPING FOR REPAIRS 



Pressure-retaining items repaired in accor- 
dance with the NBIC shall have a nameplate 
as required by Section 5.9.6. Subject to the 
acceptance of the jurisdiction and the concur- 
rence of the Inspector, nameplates may not be 
required for routine repairs. (See 5.7.2 [b]). In 
all cases, the type and extent of repairs neces- 
sary shall be considered prior to waiving the 
requirement. 



92 



NATIONAL BOARD INSPECTION CODE • PART 3 — REPAIRS AND ALTERATIONS 



5.1 3.1 FORM R-1 , REPORT OF REPAIR 



FORM R-1 REPORT OF REPAIR 

in accordance with provisions of the National Board Inspection Code 

' 1 i \2 

1. Work performed by _^ 



epair oVg.Viizair.or I (Form R No 

(53) 



2. Owner '^--' 



l'4) 



3. Location of installation 



I'D 



(address) 

5 % ; i, ,.:-", , , (6) 



4. Unit identification _ 

(l-cilCT. pressure wms1 



5. Identifying nos.: ^ 

(S. NBIC Edition/Addenda: ':' 



■ in; 



© 


C£i 






(1/ 


(9) 




i National I j<:ard \.. ) 


(jr.* 
JO) 


ci:t o 


\o 


(i.lh.rf 


v<~ 


r tnnlli 


(11) 


(.addend,:) 






(fl) 





Original Code of Construction for Item: 

L (name /section: J i\ sior) (edit on ' addenda; 

'IT 1 fi'i 

Construction Code Used for Repair Performed: ' x -- / ' '<J , 

r (nar-c.'seclion/divisonl (edition/.nid,.nd:) 

7. Repair Type: - y I I Welded I I Graphite Pressure Equipment I I FRP Pressure Equipment 

8. Description of work: jJJL 

(ra .supplemental sheet, ierni K 4. i: necessary) 



. Pressure Test, if applied '121 psi MAWP ^ 



_ psi 

9, Replacement Parts. Attached are Manufacturer's Partial Data Reports or Form R-3s properly- 
completed for the following items of this report: 
(14) 

(name i> _ par- ;-fm number, ii?M report lypc, mft;. name, or.ci identifying stamp) 



10. Remarks:. _.a3L 



CERTIFICATE OF COMPLIANCE 

1, .v^-'i , certify that to the best of my knowledge and belief the statements in this report are 

correct and that all material, construction, and workmanship on this Repair conforms to the National Board Inspection Code. 

National Board "R" Certificate of Authorization No •Qj . expires on j-ji , 

n * 0?) >M T. , (21) 

Date i=^ , v^ Signed 



(n.'ineot repair org.mi/. :inn) (authorized representative} 



I 22' 

1, ^-^ , holding a valid Commission issued by The National Board of Boiler and Pressure 

Vessel Inspectors and certificate of competency, where required, issued by the Jurisdiction of ■•?■}/ 

and employed by J^l _ of (25/ 



have inspected the work described in this report on '-ffi , and state that to the best of my knowledge 

and belief this work complies with the applicable requirements of the National Board Inspection Code. 

By signing this certicate, neither the undersigned nor my employer makes any warranty, expressed or implied, concerning 

the work described in this report. Furthermore, neither the undersigned nor my employer shall be liable in any manner for 

any personal injury, properly damage or loss of any kind arising from or connected with this inspection. 

Date ili , Signed a??/ Commissions !2§i~ 



(iris:,ee\»r) (National board and Jurisdiction No.; 

Th's form may be obtained from The National Eca'C o' Boiler anc Presstre Vessel Inspectors, 1055 Crupper Ave . Colunbjs. OH 43229 NB-65 Rev 1 1 

95 



NATIONAL BOARD INSPECTION CODE • PART 3 — REPAIRS AND ALTERATIONS 



5.1 3.2 FORM R-2, REPORT OF ALTERATION 



FORM R-2 REPORT OF ALTERATION 

in accordance with provisions of the National Board Inspection Code 



la. Construction performed by 



( 



1 . 



(naniecf "R" o'fj.inizatum res?ons:b e for cor.strjctuin) 



(53 , 



lb. Design performed by lU 



(TO Mo . Job No . etc .: 



'.name of "K" organization responsible for design) 



2. Owner i. 3 ) 



(PO No. Job No etc) 



3. Location of installation i 4 , 1 



(address) 

4.Unit identification 00 



I boiler, pressure vessel) 

5. Identifying nos.: kZJ v. 8 / 



Name of original manufacturer yfe 



r R \ 



AIL 



(± 



(iiif^.M:rJ t .: in.) _ (Xdtioiiu.^'urd Nc.) 

6. NBIC Edition/ Addenda: jfr) 



JlllLSCbCtlOIIJlO.) 



( i u : 



Original Code of Construction for Item: vJV 

Inatiu. 1 / section / division. 

Construction Code Used for Alteration Performed: 01 



(edition >'adc:cnd_D, 



(•iiinu'/si-ct:iiti,'iii\'i-.iiiii; 



ml 



(( J ;iitini\,'<)(:dt , nii.)) 



7a. Description of construction work: [ -JV 



{us? supplement.!] sheet, h'orm R-4, ir n<Yess~rv'i 



7b. Description of design scope 



: (12) 



(list 1 si:iplement,il sheet. Fcini R-t, if nece'SS.iry) 



Pressure Test, if applied '---' psi MAWP '±M psi 

8. Replacement Parts. Attached are Manufacturer's Partial Data Reports or Form R-3s properly 
completed for the following items of this report: 



M. 



(nuiiio of ua:t, item nunltiei, data repo.t tyoe, nig name, and dentilying m^rk) 



9. Remarks: \\?. 



This form may be cbtainec tram The National Board of Boiler and Pressure Vessel Inspectors, ' G55 Crupper Ave., Colurrbus, OH 43229 



NB-2PS Rev.4 



96 



NATIONAL. BOARD INSPECTION CODE • PART 3 — REPAIRS AND ALTERATIONS 



Form R-2 (back) 



<>bim "lr Mo) 



DESIGN CERT I1TCATION 

(16) 



, certify that to the best of my knowledge and belief the statements in this report are 



correct and that the Design Change described in this report conforms to the National Board Inspection Code. 

NationakBoard "R" Certificate of Authorization No. '17; expires on 

Date-to:. & Signed fr) 



;nam* of design orgaiiizatior.) (authorized reyressr.tJlive) 



CERTIFICATE OF DESIGN CHANCE REVIEW 

i 22) 
'< s - -- . holding a valid Commission issued by The National Board of Boiler and Pressure 

Vessel Inspectors and certificate of competency, where required, issued by the jurisdiction of —123} 



and employed by — Sli f Sl> have reviewed the 

design change as described in this report and state that to the best of my knowledge and belief such change complies with 

the applicable requirements of the National Hoard Inspection Code. 

By signing this certificate, neither the undersigned nor my employer makes any warranty, expressed or implied, concerning 

the work described in this report. Furthermore, neither the undersigned nor my employer shall be liable in any manner for 

any personal injury, property damage or lojjs^of any kind arising from or connected with this inspection. 

DateJ^ ... Signed _J27j ■ __ Commissions JiD 



[Nation jI Hiuti ,iriJ j-.: rim lichen 



CONSTRUCTION CERTIFICATION 

L vlSi certify that to the best of my knowledge and belief the statements in this report are 

correct and that all material, construction, and workmanship on this Alteration conforms to the National Board Inspection Code. 

NationalBoard "R" Certificate of Authorization No. _^ 17 ,' expires utt iHz 

DateCWj /at ~ Signed (21) 



(ai -hiir.7«'d signature.) 



CERTIFICATE OF INSPECTION 

(22! 
'- ->- .holding a valid Commission issued bv 1'he National Board of Boiler and Pressure 

Vessel Inspectors and certificate of competency, where required, issued by the jurisdiction of \?3; anc | 

employed by __!i±z i [ M' have inspected 

the work described in this report on ..j£°> and slate that to the best of my knowledge and belief this work 

complies with the applicable requirements of the National Board Inspection Code. 

By signing this certificate, neither the undersigned nor my employer makes any warranty, expressed or implied, concerning 

the work described m this report. Furthermore, neither the undersigned nor my employer shall be liable in any manner for 

any personal injury property damage or loss of any kind arising from or connected with this inspection. 

Date J?°v' Signed ,./ 2 i) Commissions ,'c 8 ) 

(jrs?e.-tor: (Nslionul BoarJ a:ul -iHsc-.clion no .) 



97 



NATIONAL BDARD INSPECTION CODE • PART 3 — REPAIRS AND ALTERATIONS 



A07 5.1 3.3 FORM R-3, REPORT OF FABRICATED PARTS 



FORM R-3 REPORT OF PARTS FABRICATED BY WELDING 
in accordance with provisions of the National Board Inspection Code 



Manufactured by \ } j 



© 



53 



2. Manufactured for (29J 



3. Design Condition specified by QO) 

4. Design Code J© — © 



Code design by (3], 



(W 



(35 



5. Identification of Parts 



Name of Part 


Qty. 


Line 

No. 


Manufacturer's 
Identifying No. 


Manufacturer's 
Drawing No. . MAWP 


Shop 
Hydro PSI 


Year Built 


(36) 


&) 


(38) 


© 


© 


(M) 


© 


© 



















































































































































6. Description of Parts 


















(a) Connections other than tubes 


Heads or F.nds 


(b) Tubes 


Line 
No. 


Size and 
Shape 


Material 
Spec. No. 


Thickness 
(in.) 


Shape 


Thickness 
(in.) 


Material 
Spec. No. 


Diameter 
(in.) 


Thickness 
(in.) 


Material 
Spec. No. 


©L 


(42) 


(4i) 


(44) 


J© 


© 


@ 


(41) 


— ®- 


© 


v_/- 







































































































































































































































































































7. Remarks 



J®. 



This form may be obtained 'rom The National Beard of Boiler and Pressjrc Vessel Inspectors 1055 Crupper Ave .. Coljnbus. OH 43229 



N3 23C Rev 2 



9B 



NATIONAL BOARD INSPECTION CODE • PART 3 



REPAIRS AND ALTERATIONS 



5.1 3.4.1 GUIDE FOR COMPLETING 

NATIONAL BOARD FORM "R" 

REPORTS 

1 . Name and address of the "R" Certificate 
organization that performed the work. On 

A07 Form R-2, the organization that performed 
the construction work (Line 1a) or the de- 
sign (Line 1 b). 

2. For NBIC Report Forms registered with the 
National Board, indicate the sequential 
Form R Number assigned by the "R" Cer- 
tificate organization that is registering the 
form; otherwise indicate "N/A." For re-rat- 
ing only, the Design Organization registers 
the Form R-2. Where physical work is also 
performed, the Construction Organization 
registers the Form R-2. 

3. Name and address of the Owner of the 
pressure-retaining item. 

4. Name and address of plant or facility where 
the pressure-retaining item is installed. 

5. Description of the pressure-retaining item, 
such as boiler or pressure vessel. 

6. Name of original manufacturer of the pres- 
sure-retaining item if a boiler or pressure 
vessel. If other than a boiler or pressure 
vessel, complete if known. 

7. Serial number of the pressure-retaining item 
as assigned by the original manufacturer. 

8. Identification of the pressure-retaining 
item by applicable registration number. If 
installed in Canada, indicate the Canadian 
design registration number (CRN), and list 
the drawing number under "other." 

9. Identify the year in which fabrication/con- 
struction of the item was completed. 

10. Indicate edition and addenda of the 
NBIC under which this work is being per- 
formed. 



1 1 . Indicate the name, section, division, edi- 
tion, and addenda of the original code of 
construction for the pressure-retaining item. 
Also indicate the name, section, division, 
edition, and addenda of the construction 
code used for the work being performed. If 
code cases are used, they shall be identified 
in the "Remarks" section. 

12. State exact scope of work, and attach ad- 
ditional data, sketch, Form R-4, etc., as 
necessary. If additional data is attached, so 
state. 

13. Indicate test pressure applied. 

14. To be completed for all welded pressure 
components added during the work. In- 
dicate part, item number, manufacturer's 
name, stamped identification, and data 
report type. 

15. Indicate any additional information per- 
taining to the work involved (e.g., routine 
repairs, code cases). For Form R-3 the part 
manufacturer is to indicate the extent he 
has performed any or all of the design func- 
tion. If only a portion of the design, state 
which portion. 

1 6. Type or print name of authorized represen- 
tative of the "R" Certificate I lolder. 

17. Indicate National Board "R" Certificate or 
Authorization number. 

1 8. Indicate month, day, and year that the "R" 
certificate expires. 

19. Enter date certified. 

20. Name of "R" Certificate organization that 
performed the identified work. 

21 . Signature of authorized representative. 

22. Type or print name of Inspector. 



i a i 



NATIONAL BOARD INSPECTION CODE • PART 3 — REPAIRS AND ALTERATIONS 



23. Indicate Inspector's Jurisdiction. 

24. Indicate Inspector's employer. 

25. Indicate address of Inspector's employer 
(city and state or province). 

26. Indicate month, day, and year of inspection 
by Inspector. In case of Routine Repairs 
this shall be the month, day, and year the 
Inspector reviews the completed Routine 
Repair package. 

27. Signature of Inspector. 

28. National Board commission number of 
A07 Inspector, and when required by the Juris- 
diction, the applicable State or Provincial 
numbers. 

29. Name and address of organization that 
purchased the parts for incorporation into 
the repair or alteration, if known. If built for 
stock, so state. 

30. Name of organization responsible for speci- 
fying the code design conditions. 

31 . Name of organization responsible for per- 
forming the code design, if known. 

32. Name, section, and division of the design 
code, if known. 

.33. Indicate code edition year used for fabrica- 
tion. 

34. Indicate code addenda date used for fabri- 
cation. 

35. Indicate code paragraph reference for 
formula used to establish the MAWP, if 
known. 

36. Identify name of part, such as "superheater 
header." 



37. Indicate quantity of named parts. 

38. Match line number references for identifica- 
tion of parts and description of parts. 

39. Indicate manufacturer's serial number for 
the named part. 

40. Indicate drawing number for the named 
part. 

41. Indicate Maximum Allowable Working 
Pressure for the part, if known. 

42. Use inside diameter for size: indicate shape 
as square, round, etc. 

43. Indicate the complete material specification 
number and grade. 

44. Indicate nominal thickness of plate and 
minimum thickness after forming. 

45. Indicate shape as flat, dished, ellipsoidal, 
or hemispherical. 

46. Indicate minimum thickness after forming. 

47. Indicate outside diameter. 

48. Indicate minimum thickness of tubes. 

49. Complete information identical to that 
shown on the Form R to which this sheet 
is supplementary. 

50. Indicate the Form R type. Example: Form 
R-1, Form R-2, Form R-3. 

51 . Indicate the reference line number from the 
Form R to which this sheet is supplemen- 
tary. 

52. Complete information for which there was 
insufficient space on the reference Form R. 



1 D2 



NATIONAL BOARD INSPECTION CODE • PART 3 — REPAIRS AND ALTERATIONS 



53. If applicable, purchase order, job number, 
etc., assigned by the organization perform- 



ing the work. 



54. Indicate the maximum allowable working 
pressure of the pressure-retaining item. 

55. Indicate the type of repair, e.g., welded, 
graphite pressure equipment, or fiber- 
reinforced plastic pressure equipment. 



1 D3 



NATIONAL BOARD INSPECTION CODE • PART 3 



REPAIRS AND ALTERATIONS 



A08 5.1 3.5 FORM NR-1 , NUCLEAR COMPONENTS AND SYSTEMS IN NUCLEAR POWER 

PLANTS 



FORM NK-l REPORT OF REPAIR □ OR REPLACEMENT LI 
TO NUCLEAR COMPONENTS AND SYSTEMS IN NUCLEAR POWER PLANTS 



1. Work performed bv \ J 



n,inu'.,: ' NK" ariilir.-iu-'ii.'Mi-i 



£1 



POno, yb rip., etc. 



address /rTs; 
2. Owmrr \ZJ- 



3. Name, address, and identitication of nuclear power plant 



Q 



&- 



4. System . 

5a; Items thai Required Repair or Replacement Activities 



Identification 


Construction Code 


Activity 


No. 


Type of 
Item 


Mfg. 
Name 


Mfg. 
Serial 

No. 


Nat'l Bd 
No. 


Juris. 
No. 


Other 


Year 
Built 


Name/ 
Section / 
Division 


Edition/ 
Addenda 


Code 

Case(s) 


Code 
Class 


Repair/ 
Replace 


1 


00 


(^ 


tf) 


<B) 


(P) 


(16) 


(ft 


(18) 


(19) 


(19), 


(5) 


£5) 


2 


























3 


























4 


























5 


























6 


























7 


























8 


























9 


























10 


























11 


























12 














j 











5b. Items 


nstalled During Replacement Activities 
















Identification 


Construction Code 


Type of 
Item 


Installed or 
Replaced 
5a Hem No. 


Mfg. 
Name 


Mfg. 
Serial No. 


Nat'l Bd 
No. 


Juris. 

No. 


Other 


Year 
Built 


Name/ 

Section/ 

Division 


Filition/ 
Addenda 


Code 
Case(s) 


Code 
Class 


(io) 


GO 


(22) 


© | ^ 


(25) 


(26) 


(27) 


-(§) - 


(29) 


(29) 


(29) 

















































































































































































































































M- 



6. ASMF Code Section XI applicable lor inservice inspection: 

7. ASME Code Section XI used for repairs, modifications, or replacements: 

8. Construction Code used (or repairs or replacements: 

9. Design responsibilities i^jj 



30 



■ 30 



M 4jX 



-®L 



.« 



f32) 



10. Tests conducted: I I hydrostatic I I pneumatic I — I design pressure pressure I^y psi (MPa) Code Case(s) — \^jj 

in s form nay be ob:a.ned f'om The National Board cl Boiler and Pressrc Vessel Inspectors 1055 Cruope' Aw.. Coiunbjs OH 43229 I 

1 D4 



NATIONAL BOARD INSPECTION CODE • PART 3 



REPAIRS AND ALTERATIONS 



11. Description of work ^? J 



(u=e cl proper]',' identified addilirrir.. :heot(s] or sketches) ib acceptable) 



12. Remarks 



40 



A08 



41 



CFRTIFICATF OF COMPI.TANCF 

, certify that to the best of my knowledge and belief the statements made in this report are 



1 

correct and the repair or replacement activities described above conform to Section XI of the ASME Code and the National 
Hoard Inspection Code "NR" rules. 

National Board Certificate 1 of Authorization No \ZgJ to use the "INK" stamp expires . 

"NR" Certificate Holder _@ . 

Date @ 



43 



Signed 



4f. 



(authorized ivnrescntatjve) 



(title) 



CERTIFICATE OF INSPECTION 

i^X/ , holding a valid commission issued by The National Board of Boiler and Pressure Ves- 



sel Inspectors and certificate of competency issued bv the Jurisdiction of 
(50) 



49 



of .15 



and employed by 



have inspected the repair or replacement described in this report on (52) anc | sta te that to the best of my 

knowledge and belief, this repair or replacement activity has been completed in accordance with 

Section XI of the ASME Code and the National Board Inspection Code "NR" rules. 

By signing this certificate, neither the undersigned nor my employer makes any warranty, expressed or implied, concerning 

the work described in this report. Furthermore, neither the undersigned nor my employer shall be liable in any manner for 

any personal injury, property damage, or a loss of any kind arising from or connected with this inspection. 

Date (52J , Signed (53) Commissions '.54 I 



r.iticn.ll Bewi J ■ :iJ ll 



'his form maybe obtained Iron The National Board o' Boiler ard Pressure Vesse Inspedors, 1C55 C'upperAve . Cdumbis. OH 43229 



W 



1 D5 



NATIONAL BOARD INSPECTION CDDE • PART 3 — REPAIRS AND ALTERATIONS 



A08 5.1 3.6 FORM NVR-1 , NUCLEAR PRESSURE RELIEF DEVICES 



FORM NVR-1 REPORT OF REPAIR ~] OR REPLACEMENT □ 
OF NUCLEAR PRESSURE RELIEF DEVICES 



1. Work performed by 



<D_ 



(name :<[ ceitiiiolulinka) 



^TPO Nii. 



(jdei l-ssJ 

2. Work performed for X^-X- 

3. Owner (i. 






n.i:n;,t 



irddrtss) 

4. Name, address, and identification of nuclear power plant l^y 

5. a; Repaired pressure relief device: XJ-) 

b: Name of manufacturer i^L 



c: Identifying no's. 



d: Construction Code H" 



iul 



12 



r.',', sc-inl no.) 

■if 9) 



(|3) 



14 



'rame.'.swtior 'division) 



091 



Vnirh.lill) 

19) 



6. ASMfc Code Section XI applicable for inservice inspection: fivV 

(Mi 

7. ASME Code Section XI used for repairs or replacements; y^ l) 



30 



(30 



lacdcnda! 

6n (ST) 



(a-cic.i»5ii.i; 



8. Construction Code used for repairs or replacements: 

9. E)esign responsibility '33) 



02 



jCodetW*); 



(CivleCi^W) 



10. Opening pressure: y35) Blowdown (if applicable) _(M) %. Set pressure and blowdown adjustment 

made at: \37J using -(3*9 . 



IV. Description of work: (include name and identifying number of replacement parts) (39j 



12. Remarks: '.40 I 



41 



CERTIFICATE OF COMPLIANCE 

, certify that to the best of my knowledge and belief the statements made in this report 

are correct and the repair or replacement of the pressure relief devices described above conforms to Section XI of the ASMF. 
Code and the National Board Inspection Code "VR" and "NR" rules. 



National Board Certificate of Authorization No. 
National Board Certificate of Authorization No. (42) 
Date (45) (44) 



(42) 



. to use the "VR" stamp expires _ 
to use the "NK" stamp expires 



43 



143} 



Signed _@L 



471 



CERTIFICATE OF INSPFCTION 

, Holding a valid commission issued by The National Board of Boiler and Pressure 
Vessel Inspectors and certificate of competency issued by the Jurisdiction of — (4-%! and 



4S 



employed bv _JLiQ_). 



ii£ 



have inspected the repair or replacement described in this report on \ 52j , and state that to the best of 

my knowledge and belief, this repair or replacement has been completed in accordance with Section XI of the ASME Code 
and the National Board Inspection Code "VR" and "NR" rules. 

By signing this certificate, neither the undersigned nor my employer makes any warranty, expressed or implied, concerning 
the repair or replacement described in this report. Furthermore, neither tine undersigned nor my employer shall be liable in 
any manner for any personal injury, property damage, or loss of any kind arising from or connecled with this inspection. 



Date. 



Signed 



-©- 



Commissions 



@L 



(National S<wd ,ind Jurisdiction no ) 



This lorn r.ay be obta red from The Nationa Boatd ol Boiler and Press j-e Vessel Inspectors. 1055 Crupper Ave . Coumbjs. OH 43229 



1 DS 



NATIONAL BOARD INSPECTION CDDE • PART 3 — REPAIRS AND ALTERATIONS 



5.13.6.1 GUIDE FOR COMPLETING 

NATIONAL BOARD FORM NR-1 
AND NVR-1 REPORTS 

1 . Name and address of the organization, as 
shown on the Certificate of Authorization, 
which performed the activity. 

2. Indicate the purchase order number, job 
number, etc., as applicable, assigned by 
the organization that performed the work. 

3. Name and address of the organization for 
which the work was performed. 

4. Name and address of the owner of the 
nuclear power plant. 

5. Name and address of the nuclear power 
plant and, if applicable, identification of 
the unit. 

6. Identify the system (e.g., residual heat 
removal, reactor coolant) with which the 
repair/replacement activity is associated. 

7. Describe the type of pressure relief device 
(e.g., safety valve, safety relief valve, pres- 
sure relief valve). 

8. Indicate the type of component (e.g., vessel, 
line valve, pump, piping system). 

9. Manufacturer's name of the affected item. 

10. Indicate the pressure relief device by the 
manufacturer's valve series or catalog num- 
ber. 

1 1 . Manufacturer's serial number of the affected 
item. 



15. Indicate Jurisdiction number, if applicable, 
of the affected item. 

1 6. Indicate plant tag or identification number, 
if applicable, of the affected item. 

I 7. Year the affected item was manufactured. 

18. Identify the name, section, and division of 
the original construction code for the af- 
fected item. 

1 9. Identify the edition, addenda, and as appli- 
cable, code cases, and class of the original 
construction code for the affected item. 

20. Indicate the activity performed on this item, 
e.g., repair or replacement. 

21 . Indicate the Item No. from Section 5a with 
which this replacement item is associated. 
Attach the Manufacturer's Data Report, as 
applicable. 

22. Manufacturer's name of this replacement 
item. 

23. Manufacturer's serial number of this re- 
placement item. 

24. National Board number, if applicable, of 
this replacement item. 

25. Jurisdictional number, if applicable, of this 
replacement item. 

26. Plant tag or identification number of this 
replacement item. 

27. Year this replacement item was manufac- 
tured. 



12. National Board number, if applicable, of 
the affected item. 

13. Indicate the service as steam, liquid, gas, 
air, etc. 

1 4. Indicate the pressure relief device by inlet 
size, in inches. 



28. Name, section, and division of the con- 
struction code for this replacement item. 

29. Edition, addenda, and as applicable, code 
cases and class of the construction code for 
this replacement item. 



1 D7 



NATIONAL BOARD INSPECTION CODE • PART 3 — REPAIRS AND ALTERATIONS 



30. Identify the edition, addenda, and any ap- 
plicable code cases of the ASME Section 
XI code used for the repair or replacement 
activity. 

31 . Identify the edition, addenda, and any ap- 
plicable code cases of the ASME Section XI 
code for the repair/replacement activity. 

32. Identify the edition, addenda, and any 
applicable code cases of the construction 
code for the repair/replacement activity. 

33. Identify the organization responsible for 
design or design reconciliation, if a p p I i - 
cable. 

34. Identify the type of pressure test (e.g., hydro- 
static, pneumatic, or design) and applied 
test pressure. Also indicate any code cases 
used in connection with the pressure test. 

35. Indicate the set pressure of the valve. 

36. Indicate blowdown, if applicable, as a 
percentage of set pressure. 

37. Indicate the repair organization's name and 
address. 

38. Indicate the medium (steam, air, etc.) used 
for the adjustment of set pressure and, if 
applicable, blowdown. 

39. State exact scope of work for the repair/ 
replacement activity. If necessary attach 
additional data, sketch, Form R-4, etc. If 
additional data is attached, so state. 

40. Indicate any additional information pertain- 
ing to the work. 

41 . Type or print name of authorized represen- 
tative from the certificate holder. 

42. Indicate National Board Certificate of Au- 
thorization number. 

43. Indicate month; day, and year the certificate 
expires. 



44. Name of the certificate holder which per- 
formed the identified work. 

45. Enter date certified. 

46. Signature of authorized representative from 
the certificate holder. 

47. Title of authorized representative. 

48. Type or print name of Authorized Nuclear A08 
Inspector. 

49. Indicate the jurisdiction where the work is 
performed. 

50. Indicate Authorized Nuclear Inspector's 
employer. 

51. Indicate address of Authorized Nuclear A08 
Inspector's employer (city and state or 
province). 

52. Indicate month, day, and year of inspection A08 
by the Authorized Nuclear Inspector. 



53. Signature of Authorized Nuclear 
Inspector. 



A08 



54. National Board Commission number of the A07 
Authorized Nuclear Inspector, including 
endorsements, and when required by the ™° 
Jurisdiction, the applicable State or Provin- 
cial numbers. 



1 DB 




Part 3, Section 6 

Repairs and Alterations — 

Supplements 



1 D9 



NATIONAL BOARD INSPECTION CODE • PART 3 



REPAIRS AND ALTERATIONS 



PART 3, SECTION 6 
REPAIRS AND ALTERATIONS — SUPPLEMENTS 



SUPPLEMENT 1 

STEAM LOCOMOTIVE FSRETUBE 
BOILER REPAIRS 



S1.1 GENERAL REQUIREMENTS 



S1 .1 .1 FEDERAL RAILROAD 

ADMINISTRATION (FRA) 

The FRA rules for steam locomotive boilers 
are published in the Code of Federal Regula- 
tions (CFR) 49CFR Part 230 Dated November 
1 7, 1 999. u All locomotives under FRA jurisdic- 
tion are documented on FRA Form 4 as defined 
in 49CFR Part 230. This document is the formal 
documentation of the steam locomotive boiler 
and is required to be completed prior to the 
boiler being placed in service. This document 
shall be used as the data report for the boiler, 
applicable to all repairs and alterations per- 
formed. National Board "R" Certificate Holders 
shall document their repairs and/or alterations 
on National Board Forms R-1 or R-2. These 
reports shall be distributed to the owner-user of 
the boiler, who is required to incorporate them 
into a FRA Form 1 9, which becomes an attach- 
ment to the FRA Form 4. The design margin for 
all such repairs or alterations shall not be less 
than four based on ultimate tensile strength of 
the material. 



S1.1.3 



MATERIALS 



a) The older steels used in riveted construc- 
tion were frequently rimmed steels, high in A07 
carbon, sulfur, phosphorus and hydrogen. 
The older steels were not melted to a fine 
grain practice and will typically have poor 
toughness properties. 

b) If welding is to be used to repair a pressure- 
retaining item that was manufactured using 
riveted construction, the repair organiza- 
tion should perform a chemical composi- A07 
tion analysis on the steel plate base metal 
and rivet material to determine weldability. 
Specific quantities of carbon, manganese, 
sulfur, phosphorus, and aluminum shall 

be identified and included in the analysis. 
The result of the analysis shall be accept- 
able to the Inspector and Jurisdiction when 
required. 



S1 .1 .3.1 MATERIAL LIST FOR STEAM 
LOCOMOTIVE BOILERS 



S1.1.2 REQUIREMENTS FOR WELDING 

ACTIVITIES 

a) Before performing any welding activities, 
consideration shall be given to ensure the 
weldability of locomotive boiler materials. 

b) Special jurisdictional approval may be re- 
quired prior to starting welding activity on 
locomotive boilers. 



l i D 



NATIONAL BOARD INSPECTION CODE • PART 3 — REPAIRS AND ALTERATIONS 



The following list is intended as a basic guide- 
line only and covers basic carbon steel and 
some alloy steel material specifications. Other 
alloy materials may be available for these 
applications if necessary. 



A08 



Application 

Boiler Tubes & 
Flues, Arch Tubes 
Superheater Units 


Specification 

SA-1 78 Grade A, 
SA-1 92, SA-210 


Boiler & Firebox Plate, 
Pressure Retaining Plate 


SA-285 Grade C, 
SA-515, SA-516, 
SA-203, SA-204 


Staybolts 


SA-675, SA-36, 
ASTMA-31 


Staybolt Sleeves and 
Caps 


SA-105 Forging, 
SA-675 


Boiler Braces 


SA-675, SA-36 


Rivets 


SA-675, 
SA-31 


Forged Parts & Fittings 


SA-105, SA-1 81 


Pressure-Retaining 
Steel Castings 


SA-2 1 6, A-2 ! 7 


Hollow Cylindrical 
Pressure-Retaining 
Parts 


SA-105 horgings, 
SA-675 Bar Stock 


Superheater Unit Bolts 
& Nuts 


Bolts -SA-1 93, 
Nuts -SA-1 94 


Pipe Flanges 


SA-1 81, SA-105 


Pipe 


SA-1 06, SA-53 
seamless 


Bronze Castings & 
Washout Plugs 


SB-61, SB 62, SB-148 



c) When rivets are made from SA-675, the fin- 
ished rivets must meet the physical require- 
ments of the original rivet specification or 
SA-31 Grade A or B. 

d) When staybolt material tensile strength 
is stronger than that of the firebox sheets, 
the firebox sheets deflect instead of the 
staybolts, which can result in the sheets 
developing cracks and leaking staybolts. 
In addition, high tensile strength steels are 
difficult to drive. 



SI .1.4 FORMULA AND 

CALCULATIONS FOR STEAM 
LOCOMOTIVE BOILERS 

a) Most steam locomotive boilers were manu- 
factured in the first half of the 20 ,h century 
or before. The calculations, formula, and 
shop practices used are now distant history 
and quite difficult to obtain. The rules for 
riveted construction were last published by 
ASME in Section I Code, 1971 Edition.' 2 

b) This Supplement herein, is based in part on 
the ASME Code, Section III, 1952 Edition, 12 
which was the last published edition of 
the Steam Locomotive Code. The railroad 
industry has attempted to collect the old 
formula and some shop practices. These 
have been published by The Engineering 
Standards Committee for Steam Locomo- 
tives, Inc. (ESC) as Compendium, Volume 
1, Compilation of Calculations. 13 



a) SA-516 steel is recommended for firebox 
repairs. It is a fine grain steel that accepts 
flanging and bending with less tendency to 
crack than coarse grain steels such as SA- 
515 or SA-285 Grade C. Coarse grain steels 
have, on occasion, been found to crack or 
split after complicated flanging, bending, 
and forming. 

b) SA-36 shall not be used to make any pres- 
sure-retaining part such as shells, staybolt 
sleeves, or caps. 



1 2 This Code is available from the National Board. 
1 .} Copies of The engineering Standards Committee for Steam 
Locomotives, Inc., Compendium, Volume I, Compilation of 
Calculations, may be obtained from the Strasburg Rail Road, 
P.O. Box 96, Strasburg, PA 1 7579, 71 7.687.8421 . 



1 1 1 



NATIONAL BOARD INSPECTION CODE • PART 3 



REPAIRS AND ALTERATIONS 



S1.2 LOCOMOTIVE FIRETU8E 

BOILER REPAIRS 

S1 .2.1 REPAIR OF STAYBOLT HOLES 

a) Staybolt holes may be repaired by welding, 
reaming, or retapping to a larger size or by 
installing a flush patch. 

b) If the staybolt hole was threaded and is to 
be repaired by welding, the threads shall 
be removed prior to welding. 



S1.2.2 THREADED STAYBOLTS 

(SEE FIGURE SI. 2.2) 

a) All threaded staybolts shall have either 1 1 - 
or 12-thread pitch. Staybolt threads shall 
have a good close fit in sheets. Changing 
the staybolt thread pitch from 1 1 to 12 or 
the reverse shall be considered a repair. 

b) All staybolts shorter than 8 in. (200 mm) 



in length shall have telltale holes. Staybolt 
telltale holes in existing bolts shall be 3/1 6 
in. (5 mm) to 7/32 in. (5.5 mm) in diameter 
and at least 1-1/4 in. (32 mm) deep in the 
outer end. When staybolts 8 in. (200 mm) 
or less in length are replaced, they shall be 
replaced with staybolts that have a telltale 
hole 3/16 in. (5 mm) to 7/32 in. (5.5 mm) 
in diameter their entire length or with ones 
that have a 3/1 6 in. (5 mm) to 7/32 in. (5.5 
mm) diameter hole in each end, drilled a 
minimum of 1-1/4 in. (32 mm) deep. On 
reduced body staybolts the telltale hole 
shall extend beyond the fillet and into the 
reduced section of the staybolt. 

Ball socket-type flexible staybolts may 
have telltale holes that extend from the 
threaded end of the bolt into the bolt head 
for a distance of 1/3 the spherical bolt head 
diameter. 

c) Telltale holes shall be reopened after driv- 
ing. 



FIGURE S1 .2.2 Threaded Staybolts 






( ^^» 




i i s 



NATIONAL BOARD INSPECTION CODE • PART 3 — REPAIRS AND ALTERATIONS 



d) Staybolt length shall be sized so the length 
of bolt projecting through the sheet is not 
less than 1/8 in. (3 mm) and is sufficient to 
produce a full head after driving. 

e) The thread lead of both bolt ends and both 
firebox sheets shall be synchronized to per- 
mit the bolt to be installed without stripping 
the threads. 

f) When driving staybolt heads, the boll's 
opposite end shall be bucked or braced 
to prevent damaging the bolt's threads. 
Bracing can be done several ways, such as 
using a pneumatic holder or a heavy steel 
bucking bar. Driving the heads on both 
ends of the staybolt simultaneously using 
two pneumatic rivet hammers (double gun- 
ning) is acceptable. Bolts are to be driven 
in such a manner as to expand radially the 
bolt body and threads into the sheet prior 
to forming the head. Merely driving over 
the head is not acceptable. 

g) Ball socket-type flexible staybolts shall not 
be braced by inserting a spacer under the 
cap. 

h) Installation of different diameter staybolts 
shall be considered a repair. 



d) Welded sleeves that have damaged cap 
threads shall be repaired or replaced. If 
the sleeve has wasted lo less than 60% of 
the original thickness at the threaded cap 
section, it may be repaired by cutting off 
the threaded section and welding on a 
replacement section using full penetration 
welds. 

e) Threaded or welded sleeves that are 
cracked or have wasted to less than 60% 
of the original thickness at any section 
other than the threaded cap section shall 
be replaced. 

f) Threaded sleeves that leak where screwed 
into the boiler shell or wrapper sheet shall 
be repaired. Seal welding of one pass not 
exceeding 3/16 in. (5 mm) leg size is per- 
missible for caulking purposes only. If seal 
welding is applied, the sleeve threads in 
the weld zone shall be removed prior to 
welding. 

g) New threaded sleeves seal welded after 
installation shall have the threads removed 
from the weld zone of the sleeve prior to 
welding. 

h) Threaded staybolt caps that leak shall not 
be seal welded. 



S1 .2.3 BALL SOCKET-TYPE FLEXIBLE 

STAYBOLTS, SLEEVES, AND CAPS 

a) Welded flexible staybolt sleeves shall be 
applied as shown in Figures S1 .2.3(a) thru 
S1 .2.3(e). Sleeve axis shall be in alignment 
with cenlerlinc through holes in wrapper 
and firebox sheets. 

b) Welded sleeves and welded caps that 
leak at the welds or the sleeve shall be 
repaired. 

c) Wasted caps and sleeves shall not be re- 
paired by weld buildup. 



i) Substitution of one type of flexible staybolt 
sleeve by another type shall be considered 
a repair. 

j) Where necessary for boiler expansion, ball 
socket-type flexible staybolts shall be posi- 
tioned in such a manner as to not interfere 
with boiler expansion. Where individual 
bolts are replaced, care should be taken to 
assure that the stress load of the new bolt 
is compatible to the loading on adjacent 
bolts. 

Note: Some locomotive boiler designs 
positioned the bolts by backing the bolt 
head away from the sleeve socket bottom 
a certain amount. 



1 1 3 



NATIONAL BOARD INSPECTION CODE • PART 3 — REPAIRS AND ALTERATIONS 



FIGURE S1.2.3-a 




M-.tir •«. _ ° ld w «pper Sheets 

lil^-llettric Weld 




Application of Welded 
f Typo Staybolt Sleeves. 



FIGURE S1.2.3-b 

Ball Socket-Type Flexible Staybolts 

Welded Cover Cap Type 



welded cover cap 




ball socket staybolt 



Welded Sleeve with Threaded 
Cover Cap Type 



threaded cover cap 

welded sleeve 




ball socket staybolt 



Threaded Sleeve with Threaded Cover Cap Type 



threaded cover cap 




threaded sleeve 



ball socket staybolt consisting of a 

spherical nut on a threaded 

rigid staybolt 




ball socket staybolt 



FIGURE S1.2.3-C 

Half Sleeve Repair Procedure for 
Damaged Ball Socket Flexible Stay- 
bolt Welded Sleeve 



welded sleeve damaged at 
threaded section 



■K 



remove threaded section 
down to gasket surface 




do not remove existing flexible staybolt 



1 1 4 



NATIONAL BOARD INSPECTION CODE • PART 3 — REPAIRS AND ALTERATIONS 



FIGURE S1.2.3-d 

Half Sleeve Repair Procedure for Damaged 

Ball Socket Flexible Staybolt Welded Sleeve 



half sleeve 
I 



V 
A 





thread for standard flexible 
staybolt cap and gasket 



this surface machined for 
full penetration weld joint 




FIGURE S1.2.3-e 

Half Sleeve Repair Procedure for Damaged 

Ball Socket Flexible Staybolt Welded Sleeve 



half sleeve 
nstalled with full 
penetration weld 




FIGURE S1.2.4 

Seal Welded Staybolts 




staybolt head seal welded before driving 




staybolt head seal welded after driving 




1 1 5 



NATIONAL BOARD INSPECTION CODE • PART 3 — REPAIRS AND ALTERATIONS 



S1 .2.4 SEAL WELDED STAYBOLTS 

(SEE FIGURE S1. 2.4) 



a) Replacement threaded staybolts may be 
seal welded before or after driving. 

b) Existing threaded staybolts that leak shall 
be repaired and may be seal welded. When 
used, seal welding shall not be the sole 
means of repair. 



7/32 in. (5.5 mm) in diameter and at least 
1-1/4 in. (32 mm) deep in the outer end. 
On reduced body staybolts, the telltale hole 
shall extend beyond the fillet and into the 
reduced section of the staybolt. Staybolts 
should have through telltale holes, which 
are preferred. Ball socket-type flexible stay- 
bolts may have telltale holes that extend A07 
from the welded end of the bolt into the 
bolt head for a distance of 1 i'i the spherical 
bolt head diameter. 



S1 .2.5 WELDED INSTALLATION OF 

STAYBOLTS 

a) The installation of unthreaded staybolts us- 
ing full penetration welds is permissible. 

b) All staybolts shorter than 8 in. (200 mm) 
in length shall have telltale holes. Telltale 
hole diameter shall be 3/16 in. (5 mm) to 



Where necessary for boiler expansion, ball 
socket-type flexible staybolts shall be posi- 
tioned in such a manner as to not interfere 
with boiler expansion. Where individual 
bolls are replaced, care should be taken to 
assure that the stress load of the new bolt 
is compatible to the loading of adjacent 
bolts. 



FIGURE S1.2.6 

Diagonal Braces, Gusset Braces, and Throat Sheet/Tubesheet Braces 





diagonal brace 



pin-lype diagonal brace 




throat sheet/tubesheet brace 




solid-type brace 



„sSgZ£ AS^gAg^a 




gusset brace 



FIGURE S1.2.8 
Patch Bolts 










typical patch bolt application 


typical patch bolt \ 


/ ^, ~ 


|g§=i| 


/ Vw \ 


W=^% 


J = ^P N 




£j==" - 







1 1 s 



NATIONAL BDARD INSPECTION CODE • PART 3 



REPAIRS AND ALTERATIONS 



Note: Some locomotive boiler designs 
posilioned the bolts by backing the; bolt 
head away from the sleeve socket bottom 
a certain amount. 

d) Installation of different diameter staybolts 
shall be considered a repair. 



S1.2.8 PATCH BOLTS 

(SEE FIGURE S1.2.8) 

a) Patch bolts may be replaced in kind. 

b) Seal welding of bolts is permitted. 



S1.2.6 DIAGONAL BRACES, GUSSET 

BRACES, AND THROAT SHEET/ 
TUBESHEET BRACES 
(SEE FIGURE S1 .2.6) 

a) Loose or damaged braces shall be repaired 
or replaced. 

b) Only steel braces may be repaired by weld- 
ing. All such welds shall be full penetration. 
Wrought iron braces shall not be repaired 
by welding. When repairs or alterations are 
completed, the tightness and condition of 
the braces and their staybolts, rivets, clev- 
ises, eyes, and pins shall be verified. 



S1.2.7 



THREADED STUDS 



S1.2.9 FLUES, ARCH TUBES, 

CIRCULATORS, THERMIC 
SIPHONS 



S1 .2.9.1 FLUE AND TUBE RE-ENDING 

a) Each boiler tube or flue that is repaired by 
welding is limited to not more than three 
circumferential welded joints. 

b) Re-ending is permitted provided the thick- 
ness of the tube or flue to be re-ended is 
not less than 90% of that required by Table 
S1.2.9. 

c) Re-end pieces shall be new material and 
meet the thickness requirements of fable 
S1.2.9. 



Studs threaded into the boiler or firebox sheets 
shall not be seal welded. 



FIGURE S1 .2.9.2 

Welded Installation of ArchTuSie 





l but not less than 

i 

1/4 in. (6 mm) 




"t but not less 

n 

(yi than 1/4 in. (6 mm: 



thickness of vessel shell or head, in. 

thickness of nozzle wall, in. 

dimension of partial penetration attachment welds (fillet, single bevel, or single J), measured as shown 

in figure PVV-1 6.1, in. 

not less than the smaller of 1/4 in. (6 mm) or 0.7 t mi . (inside comer welds may be further limited by a 

lesser length of projection of the nozzle wall beyond the inside face of the vessel wall) 

the smaller of 3/4 in. (19 mm) or the thickness of either of the weld parts joined by a fillet, single bevel, or 

single J-weld, in. 



1 1 V 



NATIDNAL BOARD INSPECTION CDDE • PART 3 



REPAIRS AND ALTERATIONS 



TABLE S1 .2.9 

Maximum allowable working pressures for steel tubes or flues for firetube boilers for different diameters and gages 
of tubes conforming to the requirements of spec. SA-'I 70, SA-192, SA-209, or SA-210* 



Outside 

diameter of 

tube, inches 

D 


Minimum gage, Birmingham Wire Gage (BWG), inches 


13 
t • 0.095 


12 
t = 0.109 


11 
1=0.120 


10 
t = 0.134 


9 
t = 0.148 


8 
t = 0.165 


7 
t = 0.180 


6 
t = 0.203 


5 
t ■ 0.220 


4 
t ■ 0.238 


1 


470 


690 


- 


- 


- 


— 


- 


- 




- 


1-1/2 


320 


460 


570 


720 


800 












1-3/4 


270 


400 


490 


620 


740 


890 


- 


- 


- 


- 


2 


240 


350 


430 


540 


650 


780 


900 


- 


- 


- 


2-1/4 


210 


310 


380 


480 


580 


690 


800 


960 


- 


- 


2-1/2 


"90 


280 


350 


430 


520 


620 


720 


860 


970 


1080 


3 


160 


230 


290 


360 


430 


520 


600 


720 


810 


900 


3 1/4 




210 


270 


330 


400 


480 


550 


660 


740 


830 


3-1/2 


- 


200 


250 


310 


370 


450 


510 


620 


690 


770 


4 


- 


180 


220 


270 


330 


390 


450 


540 


610 


680 


4-'/2 


- 


160 


-.90 


240 


290 


350 


400 


480 


540 


600 


5 


- 


- 


180 


?20 


260 


310 


360 


430 


490 


540 


5-3/8 




- 


160 


2C0 


240 


290 


340 


400 


450 


500 


5-1/2 


- 


- 


- 


200 


240 


290 


330 


390 


440 


4U0 


6 


- 


- 


- 


'50 


220 


260 


300 


360 


410 


450 


P = {(t-0-65)/D} x 15550 where P - maximum allowable working pressure, oouncs per square men. 
t = minimum wall thickness, inches, 
D = cuts de diameter r/ tubes, inches. 


For p-essures belcw those given in -.re table, the gage thickness shall be not ess than the minimum g ven in the table 
' Calculated vs ues cf pressure have been rounded to the next h gher unit of 1 psi. 



TABLE S1.2.9M 

Maximum allowable working pressures for steel tubes or flues for firetube boilers for different diameters and gages 

of tubes conforming to the requirements of spec. SA-1 76, SA-192, SA-209, or SA-210* 



Outside 

diameter of 

tube, mm 

D 


Minimum gage. Birmingham Wire Gage (BWG) : to mm 


13 
t = 2.4 


12 
t = 2.8 


11 
t = 3.0 


10 
t = 3.4 


9 
t = 3.8 


8 
t = 4.2 


7 
t = 4.6 


6 
t = 5.2 


5 
t = 5.6 


4 
t = 6.0 


25 


3250 


4950 


- 


- 


■ 




- 


- 


- 


- 


40 


2150 


3250 


3850 


4950 


6100 


- 


- 


- 


- 


- 


45 


1850 


2800 


3300 


4300 


5250 


6250 


- 


- 


- 


- 


50 


1650 


2450 


2850 


37C0 


4550 


5350 


6200 


- 


--- 




6C 


1450 


220C 


2550 


3300 


4050 


4800 


5550 


6700 


- 


- 


65 


1300 


195C 


2300 


2950 


3600 


4300 


4950 


5950 


6650 


7300 


75 


1100 


1650 


1950 


2500 


3050 


3600 


4200 


5000 


5600 


6150 


85 


- 


1500 


1750 


2300 


2800 


3300 


3850 


4500 


51 CO 


5650 


90 


- 


1400 


1650 


2150 


2600 


3100 


3550 


4300 


4750 


5250 


100 


- 


1250 


1450 


1850 


2300 


2700 


31 CC 


3750 


4150 


5600 


115 


- 


1100 


1300 


1650 


2050 


2400 


280C 


3300 


3750 


4100 


125 


- 


- 


1150 


1500 


185C 


2200 


250C 


3000 


3350 


3700 


135 


- 


- 


1100 


1400 


170C 


2000 


2350 


2800 


3100 


3400 


140 


- 


- 




1353 


1650 


2000 


2300 


2/50 


3050 


3350 


150 


- 


- 


- 


1250 


1550 


1800 


2100 


2500 


2800 


3-00 


P = ((1-1. 65)/D) x 1070C0 where P - maximum allowable working pressure, kilopascals (kPa), 
t . minimum wall thickness, mm, 
D = outside diameter of tubes, mm. 


For pressures below :hcse given in the table, the gage thickness shall be not less than the minimum given in the table. 
" Calculated values of pressure have oeen rounded to the next higher unit of 5C kPa 



1 1 s 



NATIONAL BOARD INSPECTION CODE • PART 3 



REPAIRS AND ALTERATIONS 



SI. 2.9.2 ARCH TUBES 



S1.2.9.4 THERMIC SIPHONS 



a) Arch tubes that are damaged or reduced to 
less than minimum required wall thickness 
shall be replaced in entirety by new one- 
piece arch tubes. Welded repairs or partial 
replacement is not permitted. Damage in- 
cludes defects such as bulging, burns, and 
cracks. 

b) When arch tubes are installed by rolling, the 
tube end shall project through the firebox 
sheet not less than 1/4 in. (6 mm) nor more 
than 3/4 in. (19 mm) before flaring. At a 
minimum the tube shall be expanded and 
flared at least 1/8 in. (3 mm) greater than 
the diameter of the tube hole. Additionally, 
the tube may be beaded and/or seal welded 
provided the throat of the seal weld is not 
more than 3/8 in. (1 mm), and the tube is 
finished rolled after welding. 

c) An arch tube installed by welding shall 
be considered a welded nozzle. Some ac- 
ceptable weld joints are shown in Figure 
S1.2.9.2 Ref. ASME Section I, Part PW 
16,1. 

d) A change in tube attachment from rolled 
to welded or welded to rolled shall be 
considered an alteration. 



a) For repairs to siphon knuckles see Repair 
of Firebox and Tubesheet Knuckles, and 
Figures SI .2.1 1 .5-a and S1 .2.1 1 .5-b. 

b) All weld repairs to the unstayed sections of 
the siphon neck and body shall be radio- 
graphically examined. 



S1 .2.9.3 CIRCULATORS 

a) All butt welds on circulators shall be radio- 
graphically examined. 

b) Welds applied to the circulator/firebox 
sheet joint shall be in accordance with 
the weld requirements for arch tubes. (See 
FigureSL 2. 9.2). 



SI. 2.9.6 RE-ROLLING OF FLUE-TUBES 
AFTER SEAL WELDING 



A08 



All flues and tubes that are installed by rolling 
and seal welding shall be re-rolled after seal 
welding is complete. 

S1.2.10 REPAIRS AND ALTERATIONS 

TO BOILER BARREL UNSTAYED 
AREAS 



S1 .2.9.3 TUBE WALL THICKNESS FOR 
ARCH TUBES 

The minimum wall thickness of replace- 
ment arch tubes shall be as shown in Table 
S1 .2.9.3. 



TABLE S1 .2.9.3 



Size 


Wall Thickness 


up to 3 in. (75 mm) OD 


8 Birmingham wire 
gage (BWC) 


more than 3 in. (75 mm) 
ODto4in. (lOOmm)OD 


7 Birmingham wire 
gage (BWG) 



a) Defects such as cracks and wastage may be 
repaired by weld buildup, a welded flush 
patch or a riveted patch. Installation of a 
riveted patch shall be considered an altera- 
tion. Prior to repairing cracks, the plate shall 
be examined for defects. Affected sections 
shall be repaired. 

b) Weld buildup shall not be used if the af- 
fected section of plate has wasted below 
60% of the minimum required thickness. 

c) If the cracked section of plate is retained 
and is to be repaired by installation of a 
riveted patch, the crack may be stopped by 
drilling stop holes at each end or removed 
by a method such as grinding, cutting, or 
machining. Results of stop drilling or crack 
removal shall be verified by NDE. 



1 1 9 



NATIONAL BOARD INSPECTION CODE • PART 3 



REPAIRS AND ALTERATIONS 



d) Welded repairs at or near riveted seams 
requiring preheating or postweld heat 
treatment shall be carefully made in order 
to prevent loosening in the riveted seams, 
especially when localized heating is used. 
Where necessary to control expansion or 
to gain access for welding, rivets at the 
defective section and to each side of it may 
be removed. Reuse of rivets and staybolts 
is prohibited. 

e) All welded repairs to boiler barrel unstayed 
areas shall be radiographically examined 



in accordance with ASME Code, Section I, 
when the size of the repaired area is greater 
than the maximum size of an unreinforced 
opening as calculated in accordance with 
the latest edition of ASME Code, Section I. 

Riveted patches may be any shape or size 
provided the lowest patch efficiency is 
equal to or greater than the lowest equiva- 
lent seam efficiency of the boiler course 
to which it is applied. Ref: ASME Code, 
Section I. 



FIGURE S1.2.9.4-a 

Locomotive Firebox Thermic Siphon Installation 






layboltboay 



thermic sipnor 



FIGURE S1.2.9.4-b 
Thermic Siphon Repair 



full penetration welds 



section on w-vv 




3E 



; h ^ 

length to suit 



flush patch on staybolt siphon body 




siphon neck repair \ full penetration weld 
radiographically 
examined after welding 



1 2D 



NATIONAL BOARD INSPECTION CODE • PART 3 



REPAIRS AND ALTERATIONS 



I) The factor of safety of all riveted patches 
shall not be less than four for locomotives 
operating under Federal Railroad Adminis- 
tration regulations. 



S1.2.11 REPAIRS AND ALTERATIONS TO 
BOILER BARREL STAYED AREA 



S1 .2.1 1 .1 FIREBOX SHEET REPAIR 

a) Cracks in all stayed firebox sheets may be 
repaired by welding or the installation of a 
flush patch. 

b) If the crack extends into a staybolt or rivet 
hole, the staybolt or rivet shall be removed 
prior to making the repair. 

A07 c) Fire cracks or thermal fatigue cracks in 
riveted seams located in the firebox that 
run from the edge of the plate into the rivet 
holes may be left in place provided they 
do not leak and there is no indication that 

A08 the seam or rivets are loose. (See Figure 
SI .2.1 1.1). 



A08 



FIGURE S1.2.11.1 

Example of Thermal Fire Crack 




S1.2.11.2 FIREBOX PATCHES 

a) Fetches may be any shape provided they are 
adequately supported by staybolts, rivets, 
tubes, or other forms of construction. Fetches 
on stayed surfaces should be designed so weld 
seams pass between staybolt rows. (See Figure 
SI .2.1 1.2). 

b) Patches are to be flush type, using full penetra- 
tion welds. If the load on the patch is carried by 



FIGURE SI .2.11.2 
Typical Firebox Patches 

This figure illustrates what would be considered a 
saw-tooth patch. Its advantage is that a maximum 
amount of welding is obtained for securing a given 
patch and by zig-zagging the weld, the weld is 
supported by three rows of staybolts instead of two. 
Its disadvantage is its irregular shape which causes 
greater difficulty in fitting and applying. 




Saw-Tooth Patch 



y...... ............ .■_. . - ....... r _.._, 
























. 


I ft. 














, -c - 
















-< 




J 


















.. .< 


i - -< 


►---« 
































j 




































' 














V 


V 


;i 


D 




















>, 
















Jl 










'< 


























































































r * 

















Rectangular Shaped Patch 




-$ — $ — ^ O ^-A-O () — o — o <^- 

Diamond Shaped Patch 



1 2 1 



NATIONAL BOARD INSPECTION CODE • PART 3 



REPAIRS AND ALTERATIONS 



other forms of construction, such as staybolts, 
A08 rivets, or tubes, radiographic examination and 
postweld heat treatment of the welds are not 
required. 

c) If the patch includes an existing riveted seam, 
the patch shall be riveted at that seam. Chang- 
ing a riveted seam to a welded seam is con- 
sidered an alteration. 

d) All rectangular or angled patches shall have ad- 
equate radius at all corners. Minimum radius to 
be not less than three times plate thickness. 

e) Patches shall fit flush on the waterside of 
the sheet. Misalignment shall not exceed 
one-quarter plate thickness on edge align- 
ment with the sheet water side. 

f) Staybolts and rivets should be installed after 
welding of patch is completed. Reuse of 
staybolts and rivets is prohibited. 

g) Weld seams parallel to a knuckle shall be 
located no closer to the knuckle than the 
point of tangency of the knuckle unless 
the weld is radiographically examined. 
Weld seams not located in the knuckle are 
preferred. (See Figure SI .2.1 1 .5-b). 



FIGURE SI. 2.1 1.3 

Stayed Firebox Sheet Grooved or Wasted 

at Mudring 

Firebox Sheets 




Mudring Rivet Mudring/ 



h) Patches shall be made from material that 
is at least equal in quality and thickness to 
the original material. 



SI .2.1 1.3 REPAIR OF STAYED FIREBOX 

SHEETS GROOVED OR WASTED 
AT THE MUDRING 

a) Grooved or wasted firebox sheets having 
greater than 60% of the minimum required 
thickness remaining may be repaired by 
weld buildup provided the wastage does 
not extend below the waterside surface of 
the mudring and the strength of the struc- 
ture will not be impaired. If extensive weld- 
ing is required, the affected area shall be 
removed and replaced with a flush patch. 

b) If the sheet thickness has been reduced to 
less than 60% of the minimum required 
thickness, the affected section shall be 
removed and replaced with a flush patch. 



FIGURE S1.2.11.4 
Mudring Repairs 



mudrin 




remove fire box sheets for access 




full penetration weld 



1 22 



NATIONAL BOARD INSPECTION CODE • PART 3 — REPAIRS AND ALTERATIONS 



d) 



If wastage and grooving extends below the 
mudring waterside surface and if the plate 
thickness remaining has been reduced to 
less than the minimum required thickness, 
the affected section shall be removed and 
replaced with a flush patch. 

Flush patches shall be arranged to include 
the mudring rivets and at least the first row 
of staybolts above the mudring. 



b) Cracked or broken mudrings may be re- 
paired by welding or installation of flush 
patches using full penetration welds. 
Patches shall be made from material that 
is at least equal in quality and thickness to 
the original material. Patches shall fit flush 
on waterside surfaces. Where necessary, 
firebox sheets on both sides of the defect 
may be removed to provide access for in- 
spection and welding. 



SI .2.1 1.4 MUDRING REPAIRS 

(SEE FIGURES!. 2.1 1.4) 



S1. 2.1 1.5 REPAIR OF FIREBOX AND 

TUBESHEET KNUCKLES 



Pitted and wasted sections of mudrings 
may be built up by welding provided the 
strength of the mudring will not be im- 
paired. Where extensive weld buildup is 
employed, the Inspector may require an 
appropriate method of NIDE for the repair. 



Welds within the points of tangency of a 
knuckle are permitted. Welds with angles 
of less than 45 degrees to the longitudinal 
axis of the knuckle shall be radiographically 
examined. (See Figures S1 .2.1 1 .5-a through 
S1.2.1T.5-f). 



FIGURE S1.2.11.5-a 

Firebox Tubesheet Knuckle Repair 



stavbolts 



knuckle 




transverse crack in 
tubesheet knuckle 



parallel crack in 
tubesheet knuckle 



tubesheet 



)0 ooo°8° 

Kn w o _ o_oX ogo 



knuckle patch welded through tube holes 



line of weld is to he as neatly 
horizontal as conditional will permit 



top flue 



flue 
sheet 



knuckle patch welded around tube holes 



FIGURE S1.2.11.5-b 

Repair of Firebox and Tubesheet Knuckles 



see layout 
method in 
Figure 
S1.2.11.5-b1 



point of tangency 
of knuckle 





welds located no closer to 
knuckle than point of tangency 
do not require radiographic 
examination 



1 23 



NATIONAL BOARD INSPECTION CODE • PART 3 — REPAIRS AND ALTERATIONS 



FIGURE S1.2.11.5-b1 

Layout Method of Determining Knuckle Weld Angle 

longitudinal 
axis point 




illustrations arc of inside surface of knuckle 



FIGURE S1.2.11.5-C 

Repair of Firebox and Tubesheet Knuckles 

Stayed Patch Applied to Butt-Welded Seam 

staybolt rows point of 

tangency of kn uckle 1 



knuckle 



A jJ" i 

-H 



<'*- patch length 

] 



tube or f 

staybolt rows 

weld seams located between staybolt rows 
and above first tube row or staybolt row 



patch length 



weld seams located between tube rows 
below staybolt rows or tube rows 



Stayed Patch Applied to Riveted Seam 

riveted seam [*■ 



I 




] 



-t-\ n.i'l 



^^ 



fr 



patch length 



patch length 



weld seam located above first tube row or staybolt row weld seam located between tube rows or staybolt rows 




n. 



Repairs Requiring Radiographic Examination of Weld Seams 



Jl 



1 



weld seam located in knuckle 



patch not supported by tubes, 
staybolts, or rivets 



1 24 



NATIONAL BOARD INSPECTION CODE • PART 3 — REPAIRS AND ALTERATIONS 



FIGURE S1.2.11.5-d 
Firebox Throat Sheet Knuckle 

typical flush patch installed with full 
penetration welds 




if access for welding or riveting is required, 
remove section of exterior or interior sheets 



FIGURE SI. 2.1 1.5-e 
Backhead Knuckle Repairs 



transverse 
weld ^ 



if access 
for welding 
and rivetin 
is required, 
remove 
section of 
exterior or 
interior sheets 




original wrapper sheet 



«:: 



new rivets • 



typical flush patch 
patch length 



— stay bo Its 



weld located between staybolt rows 



FIGURE SI .2.1 1.5-f 

Fire Door Opening Repair 




SECA-A 



patch installed with full 
penetration welds and 
either patch bolts and rivets 



flush patch installed 
with full penetration 
welds 



1 25 



NATIDNAL BOARD INSPECTION CODE • PART 3 



REPAIRS AND ALTERATIONS 



b) Any patch not supported by means other 
than the weld, such as rivets, staybolts, 
tubes, or other forms of construction, shall 
have all weld seams radiographically ex- 
amined. 

c) Patches shall be formed to proper shape 
and curvature. 

d) Wasted sections of knuckles that have 
not wasted below 60% of the minimum 
required thickness may be repaired by 
weld buildup provided the strength of the 
structure will not be impaired. Where weld 
buildup is employed, the Inspector may 
require an appropriate method of NDE for 
the repair. 

e) Wasted sections of knuckles that have 
wasted below 60% of the minimum re- 
quired thickness shall be replaced. 



paired by welding using full penetration 
welds. 

b) Damaged fubesheet holes may be repaired 
by welding. 

c) Sections of tubesheets damaged or wasted 
to less than 60% minimum required thick- 
ness shall be repaired by installing a flush 
patch using full penetration welds. 

d) Sections of tubesheets that have not wasted 
below 60% minimum required thickness 
may be repaired by weld buildup provided 
the strength of the structure will not be im- 
paired. Where weld buildup is employed, 
the Inspector may require an appropriate 
method of NDE for the repair. 



S1.2.12 SEAMS AND JOINTS 



S1.2.11.6 TUBESHEET REPAIRS 

(SEE FIGURE S1.2. 11.6) 

a) Cracked tubesheet ligaments may be re- 



F1CURES1.2.11.6 
Tubesheet Repairs 





typical tubesheet flush patches 




tubesheet welded around tube holes 




tubesheet welded through ligaments and tube holes 



S1.2.12.1 CAULKING RIVETED SEAMS 
AND RIVET HEADS 
(SEE FIGURE S1.2.12.1) 

a) Caulking refers to the sealing of plate seams 
and rivet heads by driving the edge of one 
surface onto the other by use of an impact 
tool. 

b) Riveted seams and rivet heads may be 
caulked in accordance with ASME Code 
Section I, 1971. 14 



14 This Code is available from the National Board. 



FIGURE S1.2.12.1 



caulking too 



W////ZA 




W///////& 



caulked edge of plate 



1 26 



NATIONAL BOARD INSPECTION CODE • PART 3 



REPAIRS AND ALTERATIONS 



S1.2.12.2 THREADED OPENINGS IN 
VESSEL WALLS, BUSHINGS, 
AND WELDED NOZZLES 
(WASHOUT PLUG HOLES AND 
OTHER CONNECTIONS) 

a) Threaded openings in vessel walls and 
welded nozzles with damaged threads 
that cannot be repaired by retapping or 
rethreading should be repaired by welding 
a nozzle in the sheet. The nozzle shall be of 
such a size as to not interfere with proper 
washout and inspection. 

b) Threaded bushings and nozzles found to be 
defective shall be replaced. Seal welding is 
not permitted. 

c) New threaded bushings equipped with 
shoulders may be seal welded at the shoul- 
der. 

d) New threaded bushings without shoulders 
that are seal welded after installation shall 
have the threads removed from the weld 
zone of the bushing prior to welding. 

e) Threaded holes with damaged threads may 
be repaired by weld buildup and re-tapping. 
The threads shall be removed prior to weld- 



extend less than 1-1/2 in. (38 mm) inside 
the boiler and beyond any obstacle im- 
mediately above it. The passage must be 
straight and approximately horizontal. Con- 
nections must be applied without pockets, 
traps, sags, or siphons. Tubular water gage 
glasses must be equipped with a protection 
shield. 

c) Locomotive water gage glasses shall be 
provided with one top and one bottom 
shutoff cock and a means to illuminate 
each glass. Each top and bottom shutoff 
cock or valve shall be of such through flow 
construction as to prevent stoppage by 
deposits of sediments. Straight run globe 
valve of the ordinary type shall not be used 
on such connections. (Sec Figure S1 .2.13). 
The water gage glass connection and pipe 
connection shall be fitted with a drain cock 
or valve having an unrestricted opening of 
not less than 3/8 in. (10 mm) in diameter 
to facilitate cleaning. 

d) The top and bottom water gage glass fittings 
are to be aligned, supported, and secured 
so as to maintain the alignment of the water 
gage glass. 

e) The lower edge of the steam connection 
to a water column or water gage glass in 
the boiler shall not be below the highest 



S1.2.13 FITTINGS AND GAGES 



S1.2.13.1 WATER GAGE CONNECTION 

a) Water gage glasses shall be applied so that 
the lowest water reading in the water gage 
glass of a horizontal firetuhe boiler on level 
track shall be at least 3 in. (75 mm) above 
the highest point of the tubes, flues, or 
crownsheet. 

b) The bottom mounting for water gage glass 
(and for water column if used) must not 



FIGURE S1.2.13 

Straight Run Globe Valve Not Permitted 




c 










|L___ ,.f/T _____ 

^L V -_-'■■ 















1 27 



NATIONAL BOARD INSPECTION CODE • PART 3 — REPAIRS AND ALTERATIONS 



visible water level in the water gage glass. 
There shall be no pockets, traps, sags, or 
siphons in the piping that will permit the 
accumulation of sediments. 

f) The upper edge of the water connection to a 
water gage glass and the boiler shall not be 
above the lowest visible water level in the 
water gage glass. There shall be no pockets, 
traps, sags, or siphons in the connection. 



1 2B 



NATIONAL BOARD INSPECTION CODE • PART 3 — REPAIRS AND ALTERATIONS 



1 28. 1 



NATIONAL BOARD INSPECTION CODE • PART 3 



REPAIRS AND ALTERATIONS 



SUPPLEMENT 2 

HISTORICAL BOILERS 



S2.1 SCOPE 

A07 a) This supplement is provided as a guide to 
repair and alteration of historical steam 
boilers of riveted and/or welded construc- 
tion not falling under the scope of Supple- 
ment 1. These historical steam boilers 
would include: steam tractors, traction en- 
gines, hobby steam boilers, portable steam 
boilers, and other such boilers that are 

A07 being preserved, restored and maintained 
for demonstration, viewing, or educational 
purposes. 

A07 Note: This supplement is not to be used 
for steam locomotive boilers falling under 
the requirements of the Federal Railroad 
Administration (FRA). FRA rules for steam 
locomotive boilers are published in 49 CFR 
230. Specific rules and special require- 
ments for inspection, repairs, alterations, 
and storage of steam locomotive boilers 
are identified in Supplement 1 Parts 2 and 
3oftheNBIC. 

A07 b) The rules specified in this supplement shall 
be used in conjunction with the applicable 
rules in this Code. References specified or 
contained in this Supplement may provide 
additional information to assist the user 
when applying the requirements of this 
supplement. 



S2.2 INTRODUCTION 

a) The following repair and alteration rules 
are minimum requirements for safe and 
satisfactory operation of historical boilers. 
Users of this supplement are cautioned that 
where complete details are not provided, 
the user is advised to seek technical guid- 
ance to provide good sound engineering 
evaluations and practices. 

b) Where adopted by a Jurisdiction, these 
requirements are mandatory. Where a Ju- 



risdiction establishes different requirements 
for historical boilers or where a conflict 
exists, the rules of the Jurisdiction prevail. 



S2.3 



RESPONSIBILITIES 



The owner, user and/or operator are responsible 
for ensuring that the boiler meets all the re- 
quirements of the Jurisdiction where the boiler 
is operated, including inspections, repairs, 
licensing, operating certificates, permits, and 
operator training. 

Note: It should be recognized that safety of 
these boilers is dependent upon the knowledge 
and training of the operator in proper use, re- 
pair, maintenance, and safe operation of each 
specific boiler proposed to be operated. (See 
Part 2, Supplement 2.) 



S2.4 



REPAIRS AND ALTERATIONS 



Repairs and alterations to boilers of historical A07 
nature should be performed with consideration 
towards preserving the authenticity of original 
design, while at the same time ensuring that the 
boiler is safe to operate at the pressure allowed 
by Part 2, Supplement 2. 



S2.5 



CONSTRUCTION STANDARDS 



Repairs and alterations shall conform to the re- 
quirements of the original construction standard 
insofar as possible. If the original construction 
standard is unknown or unavailable, the boiler 
shall be considered a boiler of locomotive de- 
sign and subject to the construction standard 
most applicable. The construction standard 
selected for the repair or alteration must meet 
the approval of the Jurisdiction. 



1 ZB.Z 



NATIONAL BOARD INSPECTION CODE • PART 3 



REPAIRS AND ALTERATIONS 



S2.6 



ACCREDITATION 



S2.7.1 MATERIAL LIST FOR 

HISTORICAL BOILERS REPAIRS 



A07 



a) Organizations performing welded repairs 
shall be accredited as described in 1 .6. 

A07 b) Organizations and/or individuals perform- 
ing non-welded repairs do not need to have 
an "R" stamp unless required by the Juris- 
diction. However, they must be competent 
in the type of repair they are performing. 



S2.7 



MATERIALS 



a) Materials used in making repairs shall con- 
form to the original construction standard, 
if known, or to a construction standard 
acceptable to the Jurisdiction. Carbon or 
alloy steels having carbon content greater 
than 0.35% shall not be welded. The repair 
organization is responsible for verifying 
identification of existing and replacement 
materials. 

A07 b) The older steels used in historical boiler 
A08 construction could have been supplied as 
either rimmed steel, flange or firebox qual- 
ity steel. Rimmed steel may be higher in 
carbon, sulfur, phosphorus and hydrogen 
contents that will adversely affect weld- 
ability. 

A07 c) If welding is to be used to repair a pressure- 
A08 retaining item where the existing material 
cannot be verified (unknown) the require- 
ments of Part 3 3.2.1 shall be met. Specific 
quantities of carbon, manganese, sulfur, 
phosphorus, and aluminum shall be identi- 
fied and included in the analysis. The result 
of the analysis shall be acceptable to the 
Inspector and, when required, the Jurisdic- 
tion. 



The following list is intended as a basic guide- 
line only and covers just the basic carbon steel 
and some alloy steel material specifications. 
Other alloy materials may be available for these 
applications if necessary. 



Application 


Specification 


Boiler Tubes & Hues 


SA-178CradeA, 
SA-192,SA-210 


Boiler & 
Firebox Plate 


SA-285 Grade C, 
SA-515, SA-516 


Staybolts 


SA-675, SA-36, 
ASTM A-3 1 


Boiler Braces 


SA-675, SA-36 


Rivets 


SA-675, 
ASTM A-3 1 


Forged Parts & Fittings 


SA-105, SA-181 


Pressure-Retaining 
Steel Castings 


SA-216, SA-2J7 


Hollow Cylindrical 


SA-105 Forgings 


Pressure-Retaining Parts 


SA-675 Bar Stock 


Pipe Flanges 


SA-181, SA-105 


Bronze Castings & 
Washout Plugs 


SB-61,SB-62 



A07 



a) SA-516 steel is recommended for firebox A07 
repairs. It is a fine grain that accepts flang- 
ing and bending with less tendency to crack 
than course grain steels such as SA-515 or 
SA-285 Grade C. Coarse grain steels have, 

on occasion, been found to crack or split 
after complicated flanging, bending, and 
forming. 

b) SA-36 is not to be used to make any pres- A07 
sure-retaining part such as shells. 

c) When rivets are made from SA-675, the A07 
finished rivets must meet the physical and 

test requirements of the original ASME rivet 
specification ASTM A-31 Grade A or B. 

d) When staybolt material tensile strength A07 
is stronger than that of the firebox sheets, 

the firebox sheets deflect instead of the 



1 29 



NATIONAL BOARD INSPECTION CODE • PART 3 



REPAIRS AND ALTERATIONS 



staybolts, which can result in the sheets 
developing cracks and leaking staybolts. 
In addition, high tensile strength steels are 
difficult to drive. 



dance with the approved construction standard, 
or Section IX of the ASME Code. 



S2.10 



HEAT TREATMENT 



S2.7.2 



REPLACEMENT PARTS 



Replacement pressure parts formed by casting, 
forging, or die forming, and on which no weld- 
ing has been performed shall be supplied as 
material. Such parts shall be marked with the 
material identification required by the construc- 
tion standard used for the repair. Replacement 
pressure parts fabricated by welding shall be 
manufactured by an organization certified as 
required by the construction standard used for 
the repair. When it is not possible or practical 
for a manufacturer to supply replacement parts 
fabricated by welding, an organization accred- 
ited as described in 1 .6 may fabricate the part 
with the approval of the Jurisdiction. 



S2.8 



WELDED REPAIR INSPECTION 



Prior to commencing any welded repairs to the 
pressure boundaries of historical boilers, the 
repair organization shall obtain an Inspector's 
approval of the proposed repair. The Inspector 
shall be an employee of either a Jurisdiction, 
as defined in Section 9, Glossary, or of the Au- 
thorized Inspection Agency contracted by the 
repair organization. The Inspector shall ensure 
the repairs are performed in accordance with 
the approved construction standard, and shall 
verify any nondestructive examinations or wit- 
A07 ness pressure testing of the completed repair. 



a) Preheat and postweld heat treatment may A07 
be used to assist in completion of the 
welded joint. Consideration should be 
given to the percentage of carbon content 
and to the thickness of the boiler materials 

to be welded. Required preheat and PWHT 
temperatures shall be specified on the 
qualified welding procedure specification 
being used. 

b) Postweld heat treatment shall be performed 
as required by the accepted construction 
standard, in accordance with written pro- A07 
cedures acceptable to the Inspector. 

c) Alternative postweld heat treatment meth- A07 
ods may be used with the Inspector's ap- 
proval. Welding methods that may be used 

as alternatives to postweld heat treatment 
when PWHT can not be performed are 
limited to increased preheat temperatures 
and controlled temper bead methods. (See 
2.5.3) 



S2.11 NONDESTRUCTIVE 

EXAMINATION 

The Inspector may require nondestructive ex- 
amination (RT, PT, MT, UT, and VT) as necessary 
to ensure satisfactory welded repairs have been 
accomplished. 



S2.9 



WELDING 



Welding shall be performed in accordance with 
the requirements of the approved construction 
standard in consultation with the Inspector. A 
repair organization accredited as described in 
1 .6 may use the Standard Welding Procedure 
Specifications shown in 2.3, as applicable. 
Welders shall be qualified for the welding 
processes used. Qualification shall be in accor- 



S2.12 



DOCUMENTATION 



Organizations performing repairs to historic 
boilers shall document the repair or alteration 
on Form R-1 or R-2, as applicable. Permanent 
documentation detailing repairs or alterations 
should be retained by the owner in permanent aq7 
boiler records such as an operator log book. 



1 3D 



NATIONAL BOARD INSPECTION CODE • PART 3 — REPAIRS AND ALTERATIONS 



A07 S2.13 



REPAIR METHODS 



a) Before performing any welding activity, 
consideration shall be given to ensure the 
weldability of historical boiler materials. 
Materials used for patches shall be made 
from material that is at least equal in quality 
and strength to the original material. 

A07 b) Before a repair is made to a defect in a 
welded joint or base metal, care should 
be taken to investigate its cause and to 
determine its extent and likelihood of recur- 
rence. 

A07 c) A repair of a defect, such as a crack in a 
welded joint or base material, shall not be 
made until the defect has been removed. A 
suitable nondestructive examination meth- 
od such as magnetic particle (MT) or liquid 
penetrant (PT) may be necessary to assure 
complete removal of the defect. If the defect 
penetrates the full thickness of the material, 
the repair shall be made with a complete 
penetration weld such as a double butt 
weld or a single bull weld with or without 
backing. Where circumstances indicate that 
the defect is likely to recur, consideration 
should be given to removing the defective 
area and installing a flush patch or taking 
other acceptable, corrective measures. A 
repair of a bulge or blister shall be made 
if a bulge or blister will affect the pressure 
retaining capability of the plate or lube or 
when evidence of leakage is noted. Defects 
such as cracks, grooving, and wastage may 
be repaired by weld buildup, welded repair, 
a welded flush patch, or a riveted patch as 
appropriate. 

A07 d) Welded repairs at or near riveted seams 
requiring preheating or postweld heat treat- 
ment shall be carefully made to prevent 
loosening in the riveted seams, especially 
when localized heating is used. Where 
necessary to control expansion or to gain 
access for welding, rivets at the defective 
section and to each side of it may be re- 
moved. Reuse of rivets is prohibited. 



S2.13.1 REPAIR OF THREADED 
STAYBOLT HOLES 



A07 



Staybolt holes may be repaired by welding, 
reaming, re-tapping to a larger size, or by in- 
stalling a flush patch. (See Figure S2.1 3.1). If the 
staybolt hole was threaded and is to be repaired 
by welding, the threads shall be removed prior 
to welding. 



S2.13.2 INSTALLATION OF THREADED 
STAYBOLTS 



A07 



a) Threaded staybolts shall have either 1 1 - or 
12- thread pitch. Staybolt threads shall have 
a close fit in sheets. Changing the staybolt 
thread pitch from 11 to 1 2 or the reverse 
shall be considered a repair. 

b) When staybolts 8 in. (200 mm) or less in A07 
length are replaced, they shall be replaced 
with staybolts that have a telltale hole 3/1 6 

in. (5 mm) to 7/32 in. (5.5 mm) in diameter 
their entire length or with ones that have a 
3/16 in. (5 mm) to 7/32 in. (5.5 mm) diam- 
eter hole in each end, drilled a minimum of 
1-1/4 in. (31 mm) deep. On reduced body 
staybolts the telltale hole shall extend be- 
yond the fillet and into the reduced section 
of the staybolt. (See Figure S2.1 3.2). 



FIGURE S2.13.1 

Single Staybolt Flush Patch 



A07 




^'^W:^l>:& : ; 




\0\; 



'MVM 



SfQ:;ijifi3 



-• ■• -- '_:j- : 



n. >J- ! 

... . . ■'"'.. „.■■■: 



1 3 1 



NATIONAL BOARD INSPECTION CODE • PART 3 — REPAIRS AND ALTERATIONS 



A07 c) Telltale holes shall be reopened after driv- 
ing. 

d) Staybolt length shall be sized so the length 
of bolt projecting through the sheet is not 
less than 1/8 in. (3 mm) and is sufficient to 
produce a full head after driving. 

A07 e) The thread lead of both bolt ends and both 
firebox sheets shall be synchronized to per- 
mit the bolt to be installed without stripping 
the threads. 

A07 f) When driving staybolt heads, the bolt's 
opposite end shall be bucked or braced 
to prevent damaging the bolt's threads. 
Bracing can be done several ways, such as 
using a pneumatic holder or a heavy steel 
bucking bar. Driving the heads on both 
ends of the staybolt simultaneously using 
two pneumatic rivet hammers (double gun- 
ning) is acceptable. Bolts are to be driven 
in such a manner as to expand radially the 
bolt body and threads into the sheet prior 
to forming the head. Merely driving over 
the head is not acceptable. 

A07 g) Reuse of threaded staybolts is prohibited. 



A07 



FIGURE S2. 13.2 
Threaded Staybolt 



h) Installation of different diameter staybolts A07 
shall be considered a non-welded (me- 
chanical) repair. 



S2.1 3.3 SEAL WELDING OF THREADED 
STAYBOLTS 



A07 



a) Replacement threaded staybolts may be 
seal welded before or after driving. (See 
Figure S2.13.3). 

b) Existing threaded staybolts that leak shall A07 
be repaired and may be seal welded. When 
used, seal welding shall not be the sole 
means of repair. Inspection must be done to 
ensure the material adjacent to the staybolt 

has not been materially weakened by de- 
terioration or wasting away before welding 
can be performed. 



S2.1 3.4 INSTALLATION OF WELDED 
STAYBOLTS 



A07 



The installation of unthreaded staybolts A07 
using full penetration welds is permissible. 
(See Figure S2. 13.4). 



telltale 
holes 




full length 
thread staybolt 



telltale 
shall be at 
least 

1-1/4 inch 
deep 



I.- -'■,"■. --.*.•>'■ <■.■//. 



telltale shall 
extend beyond 
tangent point of 
fillet radius 



reduced body staybolt 



1 32 



NATIONAL BOARD INSPECTION CODE • PART 3 — REPAIRS AND ALTERATIONS 



A07 



FIGURE S2.13.3 

Sea! Welding Staybolts 



.^VVVVV-A- vVvV* 



>1 



jVA'.'Vv'A'WA 



staybolt head seal welded 
before driving 



„yvwvvv''.-w 



VvWA-V.-V/A-' 



staybolt head seal welded 
after driving 



A07 b). Threaded stays may be replaced by welded- 
in stays provided that, in the judgement of 
the Inspector, the material adjacent to the 
staybolt has not been materially weakened 
by deterioration or wasting away. If stay- 
bolt hole is threaded, the threads shall be 
removed prior to welding. 

A07 c) Staybolts shorter than 8 in. (200 mm) in 
length shall have telltale holes. Telltale 
hole diameter shall be 3/16 in. (5 mm) to 
7/32 in. (5.5 mm) in diameter and at least 
1-1/4 in. (31 mm) deep in the outer end. 
On reduced body staybolts, the telltale hole 
shall extend beyond the fillet and into the 
reduced section of the staybolt. Staybolts 
should have through telltale holes, which 
are preferred. 

A07 d) Reuse of welded staybolts is prohibited. 

A07 e) Installation of different diameter staybolts 
shall be considered a repair. 



A07S2.13.5 THREADED STUDS 

a) Studs threaded into the boiler or firebox 
sheets shall not be seal welded. (See Figure 
S2.13.5). 



FIGURE S2. 13.4 
Welded Staybolts 



telltale 
shall be at 
least 1-1/4 
nch deep 




full 
penetration 



A07 



FIGURE S2.13.5 
Threaded Studs 

1 full thread 
through 

T X 




3 full threads 
. of engagement 



A07 



1 33 



NATIONAL BOARD INSPECTION CODE • PART 3 



REPAIRS AND ALTERATIONS 



b) When studs are replaced, they shall extend 
at least one full thread through the sheet on 
the opposite side of installation. Replace- 
ment studs shall have a minimum of three 
threads of engagement. 



A07S2.13.6 PATCH BOLTS 

a) Patch bolts may be replaced in kind. (See 
Figure S2. 13.6). 

b) Seal welding of patch bolts is permitted. 



A07S2.13.7 FLUE AND TUBE RE-ENDING 



FIGURE S2.13.6 
Patch Bolts 



A07 




typical patch bolt 




typical patch bolt application 



a) Each boiler tube or flue that is repaired by 
welding is limited to not more than three 
circumferential welded joints. 

A07 b) Re-ending is permitted provided the thick- 
ness of the tube or flue to be re-ended is 
not less than 90% of that required by Table 
S2.13.7. Re-end pieces shall be new mate- 
rial and meet the thickness requirements of 
Table S2. 13.7. 



A07 S2.13.8 FLUE AND TUBE INSTALLATION 

a) When boiler tubes and flues are replaced, 
the MAWP of the boiler must not exceed 
the MAWP of the tube or flue per Table 
S2.13.7. 

A07 b) The boiler shall have the ends of the tubes 
firmly rolled and beaded, or rolled and 
welded around the edge of the tube. (See 
Figure S2.1 3.8). Tube ends attached by roll- 
ing and welding are subject to the following 
provisions: 

I ) The tube sheet hole may be beveled or 
recessed to a depth at least equal to the 
thickness of the tubes. Where the hole 
is beveled or recessed, the projection 
of the tube beyond the tube sheet shall 
not exceed a distance equal to the tube 



FIGURE S2.13.8 

Acceptable Forms of Tube Attachments 



A07 





Not over 2 t nor loss 
than t but in no case 
more than 1/4 in. no r 
less than 1/8 in. 




Max t and not 
more than T/3 or 
1/8 in. whichever 
is the greater - - 




(d) 



Not less than 1 
and in no case 
less than 1/8 m- 





r Not more than T/3 
nor less than t or 
1/8 in. whichever 
is the greater 



1 34 



NATIONAL BOARD INSPECTION CODE • PART 3 



REPAIRS AND ALTERATIONS 



A07 TABLE S2 13 7 maximum allowable working pressures for stfel tubes or flues for firetube boilers for different 

DIAMETERS AND GAGFS OF TUBES CONFORMING TO THE REQUIREMENTS OF SPEC. SA-1 76. SA-192. SA-209, OR SA 210 



Outside 

diameter of 

tube, inches 

D 


Minimum gage. Birmingham Wire Gage (BWG), inches 


13 
t ■ 0.095 


12 
t = 0.109 


11 
t =0.120 


10 
t = 0.134 


9 
t = 0.148 


8 
t = 0.165 


7 
t= 0.180 


6 
t = 0.203 


5 
t = 0.220 


4 
t = 0.238 


■I 


470 


690 


- 


- 


- 


- 


- 


- 


- 


— 


'-1/2 


320 


460 


570 


720 


860 




- 


- 


- 


- 


■-3/4 


270 


400 


490 


620 


740 


890 




... 


- 


- 


2 


240 


350 


430 


540 


650 


780 


900 


- 


— 


— 


2 1/4 


2I0 


310 


380 


480 


580 


690 


800 


960 


- 


- 


2 1/? 


1 90 


280 


350 


430 


520 


620 


720 


860 


970 


1080 


3 


160 


230 


290 


360 


430 


520 


600 


720 


813 


930 


3-1/4 


... 


210 


270 


330 


400 


480 


550 


660 


740 


830 


3-1/2 




200 


250 


310 


370 


450 


510 


620 


69C 


770 


4 




180 


220 


270 


330 


390 


45C 


540 


6"0 


680 


4-1 '2 


- 


160 


190 


240 


290 


350 


40C 


480 


540 


600 


5 


- 


- 


180 


220 


260 


310 


360 


430 


490 


540 


5 3'8 


- 


- 


160 


200 


240 


290 


340 


400 


450 


500 


5-1/2 


~ 


- 


- 


20C 


240 


290 


330 


390 


440 


490 


6 


- 


... 


- 


180 


220 


26C 


300 


360 


410 


450 


P = {(:-0 65VD} x ' 5550 where P = maximum allowaole working pressure, ocuncs per square inch, 
t = minimum wall thickness, inches, 
D ■= cuts de diameter of tubes, nches. 


"cr pressures be ow those given in tne :aole, the gage thickness shall Oe not less than the minimum given in the table. 
Calculated valjes c' pressure have been mounded to the next higher unit of 10 psi 



A07 TABLE S2.1 3.7 SA maximum allowabif working pressures -oh steel tubes on flues tor firetubf rohers for different 

DIAMFTERS AND GAGES OF TUBES 10 I Hb REQUIREMENTS OF SPFC SA-176. SA-192. OR SA 210 



Outside 

diameter of 

tube, mm 

D 


Minimum gage, Birmingham Wire Gage (BWG), to mm 


13 
1 = 2.4 


12 
t = 2.8 


11 
t = 3.0 


10 
t = 3.4 


9 
t = 3.8 


8 
t = 4.2 


7 
1 = 4.6 


6 
t = 5.2 


5 
t = 5.6 


4 
t = 6.0 


25 


3250 


495C 


- 


- 




- 


— 


— 


— 




40 


2150 


3250 


3850 


4950 


6100 


- 




- 


- 


- 


45 


1850 


2800 


3300 


43C0 


5250 


6250 


- 


- 




- 


50 


1650 


2450 


2850 


3700 


4550 


5350 


6200 


- 


— 


- 


60 


1450 


2200 


2550 


3300 


4050 


4800 


5550 


6700 


— 


- 


65 


1300 


1950 


2300 


2950 


3600 


4300 


4950 


5950 


6653 


7300 


75 


'100 


1650 


n 950 


2500 


3050 


3600 


4200 


500C 


5600 


6' 50 


85 




1500 


'750 


2300 


2800 


3300 


3850 


4600 


5100 


5650 


90 


- 


1400 


1650 ' 


2150 


2600 


3100 


3550 


4300 


4750 


5250 


1C0 


- 


1250 


1450 


1850 


230C 


2700 


3100 


3750 


4150 


5600 


115 


- 


1100 


1300 


1650 


2050 


2400 


280C 


3300 


3750 


4100 


125 


- 


- 


1150 


1500 


1850 


2200 


2500 


3000 


3350 


3700 


135 


- 




IIOO 


1400 


1700 


2000 


2350 


2800 


3100 


3400 


140 


- 


- 




1350 


1650 


2000 


2300 


2750 


3050 


3350 


150 




- 




1250 


1550 


1800 


2100 


2500 


2800 


3100 


P = {C-1 65;/D; x 107000 where P - maximum allowable working pressure, kilcpascals (kPa), 
t = min mum wall th ckness. mm, 
D = outside diameter of tubes, mn 


Tor pressures below those given in the taole, the gage thick'ums shall be not ess nan the minimum given in the table. 
Calculated values o' pressure have been -ounced to the next higner unit ot DO kPa. 



1 35 



NATIONAL BOARD INSPECTION CODE • PART 3 



REPAIRS AND ALTERATIONS 



thickness. The depth of any bevel or 
recess shall not be less than the tube 
thickness or 1/8 in. (3 mm), whichever 
is greater, nor more than one-third of 
the tube sheet thickness. (See Figure 
S2.13.8[f] and [g]). 

A07 2) Where no bevel or recess is employed, 
the tube shall extend beyond the tube 
sheet not less than a distance equal to 
the tube thickness, nor more than twice 
the tube thickness. (See Figure S2.1 3.8 
[el). 

A07 3) On welded attachments, the tubes shall 
be rolled before welding and again 
rolled lightly after the welding proce- 
dure. 

A07 c) Expanding of tubes by the Prosser method 
(see Figure S2.13.8 lb]) in lieu of rolling 
may be employed in combination with any 
beaded or welded attachment method. 

A07 d) Seal welding is permissible on any type of 
beaded attachment. Where seal welding 
is employed, a single hydrostatic test of 
the boiler after seal welding shall be per- 
formed. 

A07 e) The inner surface of the tube hole in any 
form of attachment may be grooved or 
chamfered. 



S2.13.9 



S2. 13.9.1 



REPAIRS AND ALTERATIONS TO 
UNSTAYED AREAS 



A07 



WELD BUILDUP OF WASTAGE A07 
AND GROOVING IN UNSTAYED 
AREAS 



a) Weld buildup shall not be used if the affect- A07 
ed section of plate has wasted below 60% 

of the minimum required thickness per Part 
2, Supplement 2. (See Figure S2.1 3.9.1 ). 

b) Wasted sections that have wasted below A07 
60% of the minimum required thickness 
shall be repaired by installing a flush patch 
using full penetration welds. 

c) Weld buildup of wasted areas shall not A07 
exceed 100 sq. in. (65,000 sq. mm). 

d) Weld buildup is to replace material that A07 
has been lost due to wastage and groov- 
ing, and is not to replace thickness on the 
opposite side of the sheet. Weld buildup 
must be applied to the side of the sheet that 

is wasted or grooved. 

e) Prior to welding, the rivets in the wasted A07 
area should be removed. 

f) Rivets holes should be reamed after weld- A07 
ing. 



A07 f) The sharp edges of tube holes shall betaken 
off on both sides of the plate with a file or 
other tool. 



g) Welding shall not cover rivet heads. 



A07 



A07 



FIGURE S2.13.9.1 
Weld Buildup 



cross-section view 
of boiler shell 




wasted area 






a 



.thickness of original 
boiler shell 

minimum required thickness 

'60% of minimum required 
thickness 



repair by weld buildup is not permitted when sheet thickness is 
reduced below 60% of minimum thickness required 



1 36 



NATIONAL BOARD INSPECTION CODE • PART 3 



REPAIRS AND ALTERATIONS 



A07 S2.1 3.9.2 



WELDED REPAIR OF CRACKS IN 

UNSTAYED AREAS 



A07 a) Prior to repairing cracks, the plate shall 
be NDE examined for other defects. All 
affected sections shall be repaired. (See 
Figure S2. 13.9.2). 

A07 b) Cracks in stayed areas may be repaired by 
welding. Before cracks are repaired, how- 
ever, the inner surface of the plate should be 
examined for possible excessive corrosion 
or grooving. 

A07 c) Cracks in unstayed areas may be repaired 
by welding, providing the cracks do not 
extend between rivet holes in a longitudi- 
nal seam or parallel to a longitudinal seam 
within 8 in. (200 mm). The completed repair 
must be radiographed and stress relieved. 
Alternative methods in lieu of Postweld 
Heat Treatment identified in 2.5.3 may be 
used. 

A07 d) Cracks radiating from a common point (star 
cracking) shall not be repaired; installation 



A07 



FIGURE S2.13.9.2 
Unstayed Area Crack Repair 




acceptable cracks 
to repair 



unacceptable cracks 
to repair by welding 

installation of flush patch is required 



of a flush patch is required. Cracks radiating 
from a rivet hole in a girlh seam may be 
repaired if the plate is not seriously dam- 
aged. 

e) Prior to welding, the rivets into which A07 
cracks extend and the rivets on each side 

of them shall be removed. 

f) In riveted joints, tack bolts should be placed A07 
in alternating holes to hold the plate laps 
firmly. 

g) Rivets holes should be reamed after weld- A07 
ing. 

h) Welding shall not cover rivet heads. A07 



S2.1 3.9.3 WELDED FLUSH PATCHES IN A07 
UNSTAYED AREAS 

a) Welded repairs to boiler unstayed areas A07 
shall be radiographically examined in ac- 
cordance with the approved code of con- 
struction or ASME Code, Section I, when 

the size of the repaired area is greater than 
3 in. (75 mm) in diameter. The completed 
repair must be stress relieved. Alternative 
Methods without Postweld Heat Treatment 
identified in 2.5.3 may be used. 

b) The weld around a flush patch shall be a A07 
full penetration weld and the accessible 
surfaces shall be ground flush. Examples of 
flush welded patches are shown in Figure 
S2.13.9.3. 

c) Before installing a flush patch, the defective A07 
material should be removed until sound 
material is reached. 

d) The patch should be rolled or pressed to A07 
the proper shape or curvature. The edges 

of the patch should align with original 
material without overlap. Patches shall fit 
flush on the waterside of the sheet. If the 
patch includes an existing riveted seam, 



1 37 



NATIONAL BOARD INSPECTION CODE • PART 3 



REPAIRS AND ALTERATIONS 



A07 



A07 e) 



the patch shall be riveted at that seam. 
Changing a riveted seam to a welded seam 
is considered an alteration. Patches may be 
of any shape or size. If the patch is square or 
rectangular, an adequate radius, of at least 
three times the material thickness should 
be provided at the corners. Square corners 
shall be avoided. 

Material thickness of patches shall be at 
least equal to, but not greater than 1/8 in. 
(3 mm) thicker than original construction 
thickness. 



A07S2.1 3.9.4 



A07 a) 



REPAIR OF CRACKS, 
GROOVING, AND WASTAGE 
USING A RIVETED PATCH IN 

UNSTAYED AREAS 



If the cracked section of plate is retained 
and is to be repaired by installation of a 



riveted patch, the crack may be stopped A07 
by drilling stop holes at each end or 
removed by a method such as grind- 
ing, cutting, or machining. Results of 
stop drilling or crack removal shall be 
verified by NDE. (See Figure S2.1 3.9.4). 

b) Riveted patches may be installed on the A07 
boiler shell interior or exterior. 

c) Installation of a riveted patch shall be con- 
sidered an alteration. 



d) 



Riveted patches may be any shape or size A07 
provided the lowest patch efficiency is 
equal to or greater than the lowest equiva- 
lent seam efficiency of the boiler course to 
which it is applied. 



e) The design margin of all riveted patches A07 
shall not be less than four. 



A07 



FIGURE S2.13.9.3 
Unstayed Area Flush Patch 






1 3S 



NATIONAL BOARD INSPECTION CODE • PART 3 — REPAIRS AND ALTERATIONS 



FIGURE S2.1 3.9.4 
Riveted Boiler Shell Patch 

diagonal riveted patch circular riveted patch 





typical riveted patch installation 

patch 




S2.13.10.2 WELDED REPAIR OF CRACKS IN A07 
STAYED AREAS 

a) Requirements specified in S2.1 3.9.2 shall A07 
apply with the following additional require- 
ments identified below: 

1) If the crack extends into a staybolt hole, A07 
the staybolt shall be removed prior to 
making the repair. 

2) In riveted joints, tack bolts should be A07 
placed in alternating holes to hold the 
plate laps firmly. 

3) Rivets holes should be reamed after A07 
welding. 

4) Welding shall not cover rivet or staybolt 
heads. 



A07 S2.13.10 REPAIRS AND ALTERATIONS TO 
STAYED AREAS 



S2.13.10.3 WELDED FLUSH PATCHES IN 
STAYED AREAS 



A07 



A07 S2.13.10.1 WELD BUILDUP OF WASTAGE 
AND GROOVING IN STAYED 
AREAS 

A07 a) Requirements specified in S2. 13.9.1 shall 
be followed. Welding shall not cover rivet 
or staybolt heads. 

A07 b) Prior to welding the rivets and or staybolts 
in the wasted areas should be removed. 

A07 c) Threaded staybolt holes shall be retapped 
after welding. 

A07 d) Welding shall not cover rivet or staybolt 
heads. 

A07 c) Sec Figure S2.1 3. 10.3-a. 



a) The requirements identified in S2. 13.9.3 A07 
shall apply wilh (he additional require- 
ments specified below: 

1) Patches may be any shape provided A07 
they are adequately supported by stay- 
bolts, rivets, tubes, or other forms of 
construction. Patches on stayed surfaces 
should be designed so weld seams pass 
between staybolt rows. (See Figure 
S2.13.10.3). 

2) Patches are to be flush type, using A07 
full penetration welds. If the load on 

the patch is carried by other forms of 
construction, such as staybolts, rivets, 
or tubes, radiographic examination of 
the welds is not required. 

3) Staybolts and rivets should be installed A07 
after welding of patch is completed. 
Reuse of staybolts and rivets is prohib- 
ited. 

4) Weld seams parallel to a knuckle shall A07 
be located no closer to the knuckle than 



1 39 



NATIDNAL BOARD INSPECTION CODE • PART 3 — REPAIRS AND ALTERATIONS 



A07 



FIGURE S2.1 3.1 0.3 
Stayed Area Flush Patch 





the point of tangency of the knuckle 
unless the weld is radiographically 
examined. Weld seams not located in 
the knuckle are preferred. (See Figure 
S2.13.10.3-a). 



A07 S2.13.10.4 REPAIR OF STAYED FIREBOX 

SHEETS GROOVED OR WASTED 
ATTHEMUDRING 

A07 a) Mudrings of the Ogee style (knuckle) shall 
be repaired in accordance with S2 .13.11. 

A07 b) For Mudrings of the locomotive style (see 
Figure S2.13.10.4), grooved or wasted 
firebox sheets having greater than 60% of 
the minimum required thickness (see Figure 
S2. 13.9.1) remaining may be repaired by 
weld buildup provided the wastage does 
not extend below the waterside surface of 
the mudring and the strength of the struc- 
ture will not be impaired. If extensive weld- 
ing is required, the affected area shall be 
removed and replaced wilh a flush patch. 

A07 c) If the sheet thickness has been reduced to 
less than 60% of the minimum required 
thickness, the affected section shall be 
removed and replaced with a flush patch. 

A07 d) If wastage and grooving extends below the 
mudring waterside surface and if the plate 
thickness remaining has been reduced to 



FIGURE S2. 13. 10.3-a 
Knuckle Point of Tangency 



point of 
tangency of 
knuckle 




7 



kunckle 
radius 



A07 



less than the minimum required thickness, 
the affected section shall be removed and 
replaced with a flush patch. (See Figure 
S2. 13.10.4). 

e) Flush patches shall be arranged to include A07 
the mudring rivets and at least ihe first row 
of staybolts above the mudring. (See Figure 
S2.13.10.4-a). 

I) For mudrings of the locomotive style, pitted A07 
and wasted sections of mudrings may be 
built up by welding provided the strength 
of the mudring will not be impaired. Where 
extensive weld buildup is employed, the In- 
spector may require an appropriate method 
of NDE for the repair. 



1 4D 



NATIONAL BDARD INSPECTION CODE • PART 3 — REPAIRS AND ALTERATIONS 



A07 



FIGURE S2.13.10.4 
Mudring Wastage Repair 



sheet not wasted 
below mudring 

can be repaired 
by weld buildup 




L33 




sheet wasted below mudring 

must be repaired by installation of flush patch 



A07 



FIGURE S2.13.10.4-a 
Mudring Flush Patch 



A07 g) Cracked or broken mudrings may be re- 
paired by welding or installing flush patches 
using full penetration welds. Patches shall 
be made from material that is at least equal 
in strength and thickness to the original 
material. Patches shall fit flush on waterside 
surfaces. Where necessary, firebox sheets on 
both sides of the defect may be removed to 
provide access for inspection and welding. 



S2.13.11 REPAIR OF FIREBOX AND 
TUBESHEET KNUCKLES 



S2.1 3.1 1 .1 WELD BUILDUP OF WASTAGE 
AND GROOVING IN FIREBOX 

AND TUBESHEET KNUCKLES 



A07 



a) Weld buildup shall not be used if the affect- A07 
cd section of plate has wasted below 60% 

of the minimum required thickness per Part 
2, Supplement 2. (See Figure S2. 13.9.1). 

b) Wasted sections that have wasted below A07 
60% of the minimum required thickness 
shall be repaired by installing a flush patch 
using full penetration welds. 

c) Weld buildup of wasted areas shall not A07 
exceed 100 sq. in. (65,000 sq. mm). 

d) Weld buildup is to replace material that has A07 
been lost due to wastage and grooving, and 

is not to replace thickness on the opposite 
side of the sheet. Weld buildup must be ap- 
plied to the side of the sheet that is wasted 
or grooved. 



S2.1 3.1 1 .2 WELDED REPAIR OF CRACKS IN 

FIREBOX AND TUBESHEET 
KNUCKLES 



A07 



a) Prior to repairing cracks, the plate shall A07 
be NDE examined for other defects. All 
affected sections shall be repaired. 

b) Welds within the points of tangency of a A07 
knuckle are permitted. Welds with angles 

of less than 45 degrees to the longitudinal 
axis of the knuckle shall be radiographically 
examined. (See Figure S2.13.1 1 .2). 

c) Cracks radiating from a common point (star A07 
cracking) shall not be repaired; installation 

of a flush patch is required. 



1 41 



NATIONAL BOARD INSPECTION CODE • PART 3 — REPAIRS AND ALTERATIONS 



A07 



FIGURE S2.13.11.2 




Knuckle Weld Angles 




* <a__~— — 90 degrees 








45 degrees \ ~^^ 




1 


*-* 


1 


jgj3> 








^^; 1 : ; 


"""*-- -W »* r * 


45 degrees 


welds less than 45° to ■ 


/ 


the longitudinal axis of 


•"•-.* 


the knuckle shall be f-ja 




radiographically examined ll 






welds less than 45° to the 




longitudinal axis of the 


^---~~ 90 degrees 


knuckle shall be 


A*^ , \ 


radiographically examined 


/ \ 


fe> 


45 degrees \ 




° . % ; ;:: i: :::;:*fi»saisiig||s 


W+* 




,-'*{ 


: 
: ■- - 


# 


: 1 
45 degrees 


" --•»._ 


--^ 


/ 


- - 1 





A07 S2.13.11.3 WELDED FLUSH PATCHES SN 
FIREBOX AND TUBESHEET 
KNUCKLES 

A07 Any patch not supported by means other than 
the weld, such as rivets, staybolts, tubes, or 
other forms of construction, shall have all weld 
seams radiographically examined. (See Figure 
S2.13.11.3). All other requirements specified 
in S2. 13.9.3 shall be followed. 



a) Damaged tubesheet holes may be repaired A07 
by welding. 

b) Prior to welding, tubes in the wasted area 
should be removed. 

c) Tube holes should be reamed after weld- 
ing. 

d) Welding shall not cover tube ends. 



A07 S2.1 3.1 2 REPAIR OF TUBESHEETS 



A07 S2.13.12.1 WELD BUILDUP OF WASTAGE 
AND GROOVING IN 
TUBESHEETS 

All requirements of S2. 13.9.1 and S2.13.10 
shall be followed with the additional require- 
ments listed below: 



S2.13.12.2 WELDED REPAIR OF CRACKS IN A07 
TUBESHEETS 

a) The same method of repairing cracks in 
stayed areas identified in Figure S2.1 3.1 2.2 
shall be followed with the additional re- 
quirements identified below: 

1) Cracks in a tubesheet and cracks be- 
tween tubesheet ligaments may be 



1 42 



NATIONAL BOARD INSPECTION CODE • PART 3 — REPAIRS AND ALTERATIONS 



A07 FIGURE S2.13.113 
Knuckle Flush Patch 







^0 



:0W 






;!;*>'" 




STAYED PATCH APPLIED TO BUTT WELDED SEAM 
staybolt rows point of 
tangency of knuckle 



knuckle 

tube or 
staybolt rows 



3 



1 / H 

( patch length 



JLJL 



1 



patch length 



] 



weld seams located between staybolt 

rows and above first tube row or staybolt row 



weld seam located between tube 
rows below staybolt rows or tube rows 



STAYED PATCH APPLIED TO RIVETED SEAM 



riveted seam /tt\ 

S&3 



"J patch length 



] 



£?!= 



patch length 



weld seam located above first 
tube row or staybolt row 



weld seam located between 
tube rows or staybolt rows 



REPAIRS REQUIRING RADIOGRAPHIC EXAMINATION OF WELD SEAMS 



(f* 



Q 



_&A 



n 



weld seam located 
in knuckle 




patch not 
supported by 

"I tubes, staybolts, 

J or rivel 



rivets 



1 43 



NATIONAL BOARD INSPECTION CODE • PART 3 — REPAIRS AND ALTERATIONS 



repaired by welding using full penetra- 
tion welds. Before cracks are repaired, 
however, the inner surface of the plate 
should be carefully examined for pos- 
sible excessive corrosion or grooving. 

2) If the crack extends into a tube hole, the 
tube shall be removed prior to making 
the repair. 

3) Tube holes should be reamed after weld- 
ing. 

4) Welding shall not cover tube ends. 



A07 S2.13.1 2.3 WELDED FLUSH PATCHES SN 
TUBESHEETS 

a) The method of repair shall follow the same 
requirements identified in S2.13.10.3 with 
the following requirement as noted be- 
low: 



FIGURE S2.13.12.2 
Stayed Area Crack Repair 



acceptable cracks to repair 





A07 



unacceptable cracks to repair by welding 
Installation of flush patch is required 



1) Tubes, staybolts, and rivets should be 
installed after welding of the patch is 
completed. (See Figure S2.13.12.3). 



A07 



FIGURE S2.13.12.3 
Tubesheet Flush Patch 



|IMFiH[J!^JTi»€TH*iJl 



flush patch welded around 
tube holes 



flush patch welded 

through tube holes 

and ligaments 















1 44 



NATIONAL BOARD INSPECTION CODE • PART 3 



REPAIRS AND ALTERATIONS 



A07 S2.13.13 SEAMS, JOINTS, AND RIVETS 



b) Such holes shall not be punched in material 
more than 5/8 in. in thickness. 



A07 S2.13.13.1 CAULKING RIVETED SEAMS 
AND RSVET HEADS 
SEE FIGURE S2.13.13.1 

a) Caulking refers to the sealing of plate seams 
and rivet heads by driving the edge of one 
surface onto the other by use of an impact 
tool. 

b) The plate edges should be beveled to an 
angle not sharper than 70 degrees to the 
plane of the plate and as near thereto as 
practicable. 

c) Caulking shall be done with a tool of such 
form that there is no danger of scoring or 
damaging the plate underneath the caulk- 
ing edge, or splitting the caulked sheet. 

d) Riveted seams and rivet heads may be re- 
caulked after repairs to tighten joint. 



A07 S2.13.13.2 RIVET HOLES 

a) All holes for rivets in plates, buttstraps, 
heads, stays, and lugs shall be drilled; or 
they may be punched al least 1/8 in. less 
than full diameter for material not over 5/1 6 
in. in thickness and at least 1/4 in. less than 
full diameter for material over 5/1 6 in. 



c) For final drilling or reaming the hole to full 
diameter, the parts shall be firmly bolted in 
position by tack bolts. 

d) The finished holes must be true, clean, and 
concentric. 



S2.13.13.3 ASSEMBLY OF RIVETED JOINTS A07 

After drilling or reaming rivet holes, the plates 
shall be separated, the burrs and chips re- 
moved, and the plates reassembled. Barrel pins 
fitting the holes and tack bolts to hold the plates 
firmly together shall be used. 



S2.1 3.1 3.4 RIVETING A 07 

a) Rivets shall be so driven as to fill the holes 
preferably by a machine that maintains the 
pressure until no part of the head shows 
red in the daylight. Barrel pins fitting the 
holes and tack bolts to hold the plates 
firmly together shall be used. A rivet shall 
be driven on each side of each tack bolt 
before removing the tack bolt. 

b) Rivets shall be of sufficient length to com- 
pletely fill the rivet holes and form heads 
at least equal in strength to the bodies of 



A07 FIGURE S2.13.13.1 
Rivet Heads 





. :..../ .:■■ ■- '. . ■ :■■;■■' ■■. : ■■■■■■. 






1 45 



NATIONAL BOARD INSPECTION CODE • PART 3 



REPAIRS AND ALTERATIONS 



the rivets. Forms of finished rivet heads 
that will be acceptable are shown in Figure 
S2. 13. 13.4. 



A07 S2. 13.1 3.5 SEAL WELDING SEAM, JOINTS, 
AND RIVET HEADS 

a) Prior to welding the area should be ex- 
amined to assure that there are no cracks 
radiating from the rivet holes. (See Figure 
S2. 13. 13.5). 

b) Seal welding should not be performed if 
cracks are present in riveted areas. 

c) Seal welding shall not be considered a 
strength weld. 



S2. 13.14 REPAIR OF OPENINGS A07 



S2.1 3.14.1 REPAIR OF THREADED A07 

OPENINGS 

a) Threaded holes with damaged threads may 
be repaired by weld buildup and re-tap- 
ping. The threads shall be removed prior 
to welding. 

b) Threaded openings with damaged threads 
that cannot be repaired by re-tapping or re- 
threading should be repaired by welding a 
flush patch or a connection in the sheet. 

c) The connection shall be of such a size 
as to not interfere with proper operation, 
washout and inspection. 



A07 



FIGURE S2.13.13.5 

Seal Welding Seam and Rivet Head 




throat 

approximately 
1/8 in. (3 mm) 




1 46 



NATIONAL BOARD INSPECTION CODE • PART 3 



REPAIRS AND ALTERATIONS 



A07 



FIGURE S2.1 3.1 3.4 

American National Standard Large Rivets 



I (ANSI B18.1.2-1972, R1989) 









See Note 3- 


7 ,| 




















j o X 1 ? 

1/ H 


A i-° \ . H / I \ H / 

l^s\\ i I VI / 


- — S-B-fv < 


i 


h 


« — Ld* 


Hi 




~kM~»"T It* \ m ^ * 
— - — HA *j I L I 


'1 
1 


U A_| 

i 
j-D- 


'I 




• — 4S23 




L_^C22^ - 094 L — kzz$ ' 


'"""' 4L/ ( '£l 








Button Head 


High Button Cone Head Pan Head 




Nom. 

Body 

Diam. 

Dt 


Head Diam. A 


Height H 


Head Diam. A 


Height H 


Mfd. 


Driven 


Mfd. 


Driven 


Mfd. 


Driven 


Mfd. 


Driven 


Note 1 


Note 2 


Note 1 


Note 2 


Note 1 


Note 2 


Note 1 


Note 2 


Button Head 


High Button Head (Acorn) 


1/2 


0.875 


0.922 


0.375 


0.344 


0.781 


0.875 


0.500 


0.375 


5/8 


1.094 


1.141 


0.469 


0.438 


0.969 


1 .062 


0.594 


0.453 


3/4 


1.312 


1.375 


0.562 


0.516 


1.156 


1.250 


0.688 


0.531 


7/8 


1.531 


1.594 


0.656 


0.609 


1.344 


1 .438 


0.781 


0.609 


1 


1.750 


1.828 


0.750 


0.688 


1.531 


1.625 


0.875 


0.688 


1-1/8 


1.969 


2.062 


0.844 


0.781 


1.719 


1.812 


0.969 


0.766 


1-1/4 


2.188 


2.281 


0.938 


0.859 


1 .906 


2.000 


1.062 


0.844 


1 -3/8 


2.406 


2.516 


1.031 


0.953 


2.094 


2.188 


1.156 


0.938 


1-1/2 


2.625 


2.734 


1.125 


1.031 


2.281 


2.375 


1 .250 


1.000 


1 -5/8 


2.844 


2.969 


1.219 


1.125 


2.469 


2.562 


1.344 


1.094 


1-3/4 


3.062 


3.203 


1.312 


1.203 


2.656 


2.750 


1.438 


1.172 


Cone Head 


Pan Head 


1/2 


0.875 


0.922 


0.438 


0.406 


0.800 


0.844 


0.350 


0.328 


5/8 


1.094 


1.141 


0.547 


0.516 


1 .000 


1.047 


0.438 


0.406 


3/4 


1.312 


1.375 


0.656 


0.625 


1.200 


1 .266 


0.525 


0.484 


7/8 


1.531 


1.594 


0.766 


0.719 


1.400 


1 .469 


0.612 


0.578 


1 


1.750 


1.828 


0.87.5 


0.828 


1.600 


1 .687 


0.700 


0.656 


1-1/8 


1.969 


2.063 


0.984 


0.938 


1.800 


1.891 


0.788 


0.734 


1-1/4 


2.188 


2.281 


1.094 


1.031 


2.000 


2.094 


0.875 


0.812 


1-3/8 


2.406 


2.516 


1 .20.3 


1.141 


2.200 


2.312 


0.962 


0.906 


1-1/2 


2.625 


2.734 


1.312 


1.250 


2.400 


2.516 


1.050 


0.984 


1 -5/8 


2.844 


2.969 


1 .422 


1.344 


2.600 


2.734 


1.138 


1.062 


1-3/4 


3.062 


3.203 


1.531 


1.453 


2.800 


2.938 


1.225 


1.141 



All dimensions are given in inches. 

t Tolerance lor diameter of body is plus and minus from nominal and for 1/2-inch size equals +0.020, -0.022; for size 5/8 to 
1-inch, incl., equals +0.030, -0.0251 for sizes 1-1/8 and 1 1/4-inch equals +0.035. -0.027; for sizes 1-3/8 and 1-1/2-inch equals 
+0.040, -O.OfiO; for sizes I 5/8 and 1-3/4-irx h equals +0.040, -0.037. 

Note 1 : Basic dimensions of head as manufactured. 

Kote 2: Dimensions of manufactured head after driving and also driven head. 

Note 3: Slight flat permissible within the specified head-height tolerance. 

The following formulas give the basic dimensions for manufactured shapes: Button Head, A = 1 .750D; H = 0.750D; C = 
0.885O. High Button Head, A = 1.500O - 0.031; H = 0.750D + 0.125; f - 0.750D - 0.281; C = 0.750D - 0.281. Cone Head, 
A = 1 .750D; 6 ~ 0.93813; H = 0.875D. Pan Head, A = 1 .600D; B = 1 .000D; H - 0.700D. Length / is measured parallel to the ' 
rivet axis, from the extreme end to the bearing surface plane for flat bearing surface head-type rivets, or to the intersection of the 
head top surface witti the head diameter for countersunk head-type rivets. 



1 47 



NATIONAL BOARD INSPECTION CODE • PART 3 



REPAIRS AND ALTERATIONS 



A07 



FIGURE S2.13.13.4 continued 



American National Standard Large Rivets 


— I (ANS! B18.1.2-1972, R1989) 






r^ 


1 




. IIL _ \ 








~A& 


->"" 


~>^^v - 




<\ 


,. j *..,=J, ... 




V 


f , _.', M^V ' 


^Mat/k 




l 

« — (-D- 

i- 


1 




1 


Flal Countersu 


ik Head _ *^ 








Oval Cc 


untersunk 1 lead 








rial and Oval Countersunk Head 










Head 


Oval 


Oval 




Body Diameter, D 


Head Diameter, A 


Depth, H 


Crown 
Height,* 


Crown 
Radius,* 
















Nominal* 


Max. 


Min. 


fvlax.t 


Min.± 


Ret. 


C 


C 


1/2 


0.500 


0.520 


0.478 


0.936 


0.872 


0.260 


0.095 


1.125 


5/8 


0.625 


0.655 


0.600 


1.194 


1.112 


0.339 


0.119 


1.406 


3/4 


0.750 


0.780 


0.725 


1.421 


1.322 


0.400 


0.142 


1 .688 


7/8 


0.875 


0.905 


0.850 


1.647 


1.532 


0.460 


0.166 


1.969 


1 


1 .000 


1.030 


0.975 


1.873 


1.745 


0.520 


0.190 


2.250 


1-1/8 


1.125 


1.160 


1.098 


2.114 


1 .97.3 


0.589 


0.214 


2.531 


1-1/4 


1.250 


1.285 


1.223 


2.340 


2.199 


0.650 


0.238 


2.812 


1-3/8 


1 .375 


1.415 


1 .345 


2.567 


2.426 


0.710 


0.261 


3.094 


1-1/2 


1.500 


1 .540 


1.470 


2.793 


2.652 


0.771 


0.285 


3.375 


1 -5/8 


1.G25 


1.665 


1.588 


3.019 


2.878 


0.831 


0.309 


3.656 


1 -3/4 


1.750 


1.790 


1.713 


3.262 


3.121 


0.901 


0.332 


3.938 









f H^^an 












* 

K 

» 




r 




I 

— 4d- 








Swell Neck 


^— «sS£5 










Swell Neck* 




Body Diameter, D 


Diameter Ur 


tder Head, £ 


Neck 
Length, K* 


Nominal* 


Max. 


Min. 


Max. (Basic) 


Min. 


1/2 


0.500 


0.520 


0.478 


0.563 


0.543 


0.250 


5/8 


0.625 


0.655 


0.600 


0.688 


0.658 


0.312 


3/4 


0.750 


0.780 


0.725 


0.813 


0.783 


0.375 


7/8 


0.875 


0.905 


0.850 


0.938 


0.908 


0.438 


1 


1.000 


1.030 


0.975 


1.063 


1.033 


0.500 


1-1/8 


1.125 


1.160 


1.098 


1.188 


1.153 


0.562 


1-1/4 


1.250 


1.285 


1.223 


1.313 


1.278 


0.625 


1 -3/8 


1.375 


1.415 


1.345 


1.438 


1.398 


0.688 


1-1/2 


1.500 


1.540 


1.470 


1 .563 


1.523 


0.750 


1-5/8 


1 .625 


1.665 


1.588 


1.688 


1.648 


0.812 


1 -3/4 


1.750 


1.790 


1.713 


1.813 


1 .773 


0.875 



All dimensions are given in inches. * Basic dimension as manufactured. 

t Shard-edged head. + Rounded or flat-edged irregularly shaped head (heads are not machined or trimmed.) 

* The swell neck is applicable to all standard forms of large rivels except the flat countersunk and oval countersunk-head types. 

The following formulas give the basic dimensions for manufactured shapes: Flat Countersunk I lead. A - 1.810D; H = 1 .192/) 

(Max A - 0)12; included angle Q of head = 78 degrees. Oval Countersunk Head, A = 1.81 0D; H = 1.192 (Max. A - D)/2; 

included angle of head = 78 degrees. Swell Neck, E - D + 0.063; K = 0.500D. Length L is measured parallel to the rivet axis, 

from the extreme end to the bearing surface plane for flat bearing surface head-type rivets, or to the intersection of the head top 

surface with the head diameter for countersunk head type rivets. 

Note: l-or more information see ANSI b 18. 1.2. A copy can be obtained in the machinist handbook. 



1 4S 



NATIONAL BOARD INSPECTION CODE • PART 3 — REPAIRS AND ALTERATIONS 



A07 d) Patches are to be flush type, using full pen- 
etration welds. If the load on the patch is 
carried by other forms of construction, such 
as staybolts, rivets, or tubes, radiographic 
examination of the welds is not required. 

A07 e) Threaded bushings and piping found to be 
defective shall be replaced. Seal welding 
is not permitted. 



Supplement 2. (See Figure S2.1 3.9.1 ). Weld A07 
buildup of wasted areas shall not exceed 
100 sq. in. (65,000 sq. mm). 

b) Weld buildup is to replace material that has A07 
been lost due to wastage and grooving, and 
is not to replace thickness on the opposite 
side of the sheet. Weld buildup must be ap- 
plied to the side of the sheet that is wasted 
or grooved. 



A07 S2. 13.14.2 REPAIR OF HANDHOLE 

OPENINGS 

a) Weld buildup shall not be used if the af- 
fected section of plate has wasted below 
60% of the original thickness per Part 2, 



Wasted sections that have wasted below A07 
60% of the minimum required thickness 
shall be repaired by installing a flush patch 
using full penetration welds or a by the in- 
stallation of a ring on the inside (pressure 
side) of the sheet. (See Figure S2. 13. 14.2). 



A07 



FIGURE S2.13.14.2 

Repair of Handhole Opening 



jSgstimimmmmmmsmKammmmmimgmimmmtmamiai 

# 

m I 

» 

lf§§|! 

^^«;$pppr"**^ 



SIKH*' 




plate lap should not be less than 1/2 in. (1 3 mm) 



standard 

handhole 

size 



fillet weld 



A07 



FIGURE S2.13.14.3 

Fusible Plug Repair Using Half Coupling 




1 49 



NATIONAL BOARD INSPECTION CODE • PART 3 — REPAIRS AND ALTERATIONS 



A07 S2. 13.14.3 REPAIR OF FUSIBLE PLUG 

OPENING 



A07 a) Threaded holes with damaged threads may 
be repaired by weld buildup and re-tap- 
ping. The threads shall be removed prior 
to welding. 

A07 b) Threaded openings with damaged threads 
that cannot be; repaired by re-tapping or 
rethreading should be repaired by welding 
a flush patch or a connection in the sheet. 
The connection shall be of such a size as 
to not interfere with proper operation. The 
coupling shall be welded flush, using a full 
penetration weld, with the fireside and must 
not project higher than 1/2 in. (13 mm) from 
the water side. (See Figure S2.13.14.3). 

A07 c) Patches are to be flush type, using full pen- 
etration welds. If the load on the patch is 
carried by other forms of construction, such 
as staybolts, rivets, or tubes, radiographic 
examination of the welds is not required. 



1 5D 



NATIONAL BOARD INSPECTION CDDE • PART 3 — REPAIRS AND ALTERATIONS 



SUPPLEMENT 3 

REPAIR AND ALTERATION OF 
GRAPHITE PRESSURE 

EQUIPMENT 



S3.1 



SCOPE 



Repairs to graphite pressure equipment require 
the use of certified impregnated graphite and 
cement. The determining factor in establish- 
ing the desired material properties is the resin 
impregnation cycle. If the resin impregnation 
cycle is not controlled, it is not possible to meet 
the minimum design values. 



S3.2 



REPAIRS 



The requirements provided in this supplement 
shall apply, insofar as they are applicable to 
graphite pressure equipment. Graphite specific 
requirements include: 

a) Organizations performing repairs shall 
be accredited as described in 1.6, as ap- 
propriate for the scope of work to be per- 
formed. 

b) When the standard governing the original 
construction is not the ASME Code, repairs 
or alterations shall conform to the edition 
of the original construction standard or 
specification most applicable to the work. 
Where the original code of construction is 
unknown, the edition and addenda of the 
ASME Code most appropriate for the work 
shall be used, provided the "R" Certificate 
Holder has the concurrence of the Inspector 
and the Jurisdiction where the pressure- 
retaining item is installed. 

c) The materials used in making repairs or 
alterations shall conform to the require- 
ments of the original code of construction 
except as provided in subparagraph (j). The 
"R" Certificate Holder is responsible for 
verifying identification of existing materi- 



als from original data, drawings, or unit 
records and identification of the materials 
to be installed. 

d) When ASME is the original code of con- 
struction, replacement parts subject to 
internal or external pressure, which require 
shop inspection by an Authorized Inspec- 
tor, shall be fabricated by an organization 
having an appropriate ASME Certificate of 
Authorization. The item shall be inspected 
and stamped as required by the applicable 
section of the ASME Code. A completed 
ASME Manufacturer's Partial Data Report 
shall be supplied by the manufacturer. 

e) When the original code of construction 
is other than ASMF, replacement parts 
subject to internal or external pressure 
shall be manufactured by an organization 
certified as required by the original code of 
construction. The item shall be inspected 
and stamped as required by the original 
code of construction. Certification to the 
original code of construction as required 
by the original code of construction or 
equivalent shall be supplied with the item. 
When this is not possible or practicable, the 
organization fabricating the part may have a 
National Board Certificate of Authorization; 
replacement parts shall be documented on 
Horm R-3 and the "R" symbol stamp applied 
as described in Section 5 of this Part. 

f) Organizations performing repairs under 
an "R" stamp program shall register such 
repairs with the National Board. 

g) Before signing the appropriate NBIC Form, 
the Inspector shall review the drawings, 
witness any required pressure test, ensure 
that the required nondestructive examina- 
tions have been performed satisfactorily, 
and that the other functions necessary to 
assure compliance with the requirement 
of this Code have been performed. 



1 5 1 



NATIONAL BOARD INSPECTION CODE • PART 3 



REPAIRS AND ALTERATIONS 



h) Pressure-retaining items repaired in ac- 
cordance with the NBIC shall be marked 
as required by Section 5 of this Part. The 
letter "G" shall be applied to the nameplate 
under the "R" stamp when graphite repairs 
are made. The alternate procedure defined 
in 5.10 maybe used in lieu of the stamping 
and nameplate attachment requirements of 
Section 5 of this Part. 

i) Legible copies of the completed Form R-1 , 
together with attachments, shall be distrib- 
uted to the owner or user, the Inspector, the 
Jurisdiction if required, and the Authorized 
Inspection Agency responsible for inservice 
inspection. Form R-1 shall be registered 
with the National Board. Distribution of 
Form R-1 and attachments shall be the re- 
sponsibility of the organization performing 
the repair. 

j) Graphite parts that have previously been in 
service in one pressure vessel should not be 
used in a second vessel without prior ap- 
proval of the owner. Consideration should 
be given to the service condition of the 
previous process and possible contamina- 
tion of the subsequent process. 

k) Blind cracks and delaminations may not be 
repaired by cement injection only. 

I) Cracks and porosity in tubes may not be 
repaired. Cracked and porous sections may 
be removed so that the remainder of the 
tube may be used. Individual tube sections 
shall not be less than 24 in. (610 mm) in 
length, and the number of segments in a 
tube shall not exceed the quantity listed in 
Table S3. 2. 

m) Cementing procedure specifications shall 
be qualified by the repair organization. The 
specifications shall be qualified as required 
by the code of construction. Cementing 
procedure qualification shall be verified 
by the Inspector. 



TABLE S3. 2 — 

Permitted Quantity of Tube Segments 



Total Tube 


Num 


bei 


•of 


Number 


Length, ft. I'm) 


Tube 


Segments 


of Joints 


6 (1 .8) 






1 





9(2.7; 






2 


1 


12 C-5.7) 






3 


2 


14 (4.3) 






3 


2 


16(4.9) 






4 


3 


18(5.5.) 






4 


3 


20(6.1) 






4 


3 


22 (6.7) 






4 


3 


24(7.3) 






5 


4 


27(8.2) 






5 


4 



n) Cementing technicians shall be qualified 
by the repair organization. The technicians 
shall be qualified as required by the code 
of construction. A cementing technician is 
any individual who is responsible for proper 
joint preparation, cleaning parts to be 
joined, mixing cement, applying cement, 
securing the joint during the curing process, 
and controlling the curing process. 

o) All records shall be made available to the 
Inspector. 

p) Completed repairs shall be subjected to a 
pressure test. The test pressure shall not be 
less than the maximum allowable working 
pressure or twice the operating pressure, 
whichever is lower. The test pressure shall A08 
be maintained for 30 minutes. 

q) Reimpregnation may be used to reduce 
porosity in an existing graphite component, 
which will improve the existing graphite 
component's performance and expected 
life. Reimpregnation of graphite shall not 
be considered a means to restore original 
strength, nor shall it be considered a means 
to restore the original depth of impregna- 
tion. 



1 5Z 



NATIONAL BOARD INSPECTION CODE • PART 3 



REPAIRS AND ALTERATIONS 



S3.3 REPAIRS OF A ROUTINE 

NATURE 

a) The following repairs shall be considered 
routine, and shall comply with 3.3.2. 

1) Machining — routine repair shall not 
include the machining of pressure- 
retaining parts with the exception of 
minor machining for cleaning and joint 
preparation not to exceed 1/32 in. (0.8 
mm) of material thickness. 

2) Repair of Gasket Surfaces — re-ma- 
chining of gasket surfaces, re-serrating, 
or flattening is permitted if the design 
thickness is maintained. 

3) Replacing Individual Tubes — drilling 
out and replacing lubes with new tubes 
or repaired tubes. Only certified materi- 
als shall be used for this repair. 

4) Nozzle Replacement — replacement of 
nozzles by removing the old nozzle and 
cementing a new nozzle in place. This is 
applicable for nozzles with inside diam- 
eters not exceeding 18 in. (460 mm). 

5) Plugging Tubes — plugging individual 
tubes using accepted procedures. 

6) Surface Repair — surface repair by 
installation of plugs or inlay material 
shall not exceed 1 cu. in. (16 cu. cm) 
of total volume. Connected repairs are 
not to be considered routine. 

7) Replacement or Addition of Non-Load 
Bearing Attachments to Pressure- 
Retaining Item — For attachment of 
non-load bearing attachments to pres- 
sure-retaining items, the cementing 
procedure specification need only be 
qualified for the pressure part and ce- 
ment to be used. 

b) Complete records of these routine repairs 
shall be kept for review by the Inspector. 



The records shall include the number of 
tubes replaced or plugged and their loca- 
tion within the tube bundle. 



S3. 4 



ALTERATIONS 



a) The requirements provided in this Section 
shall apply, insofar as they are applicable to 
the materials discussed herein. Completed 
alterations shall be subjected to a pressure 
test not less than that required by the code 

of construction. The test pressure shall be A08 
maintained for a minimum of 30 minutes. 
The pressure shall be reduced to MAWP 
and maintained for inspection. 

b) The nameplate shall be applied in accor- 
dance with Section 5 of this part. The letter 
"G" shall be applied to the nameplate un- 
der the "R" stamp when graphite alterations 
are made. The alternate procedure defined 
in 5.10 maybe used in lieu of the stamping 
and nameplate attachment requirements of 
Section 5 of this Part. 

<:) Organizations performing alterations under 
an "R" stamp program shall register such 
alterations with the National Board. 



S3.5 



S3.5.1 



REPAIR GUIDE FOR 
IMPERVIOUS GRAPHITE 



INTRODUCTION 



a) This section is intended to provide sug- 
gested process and technique details for 
repairs. This section should be used as a 
guide by the repair organization in devel- 
oping specific repair procedures. 

b) Damage to domes (heads), tubesheets, or 
nozzles is invariably a sign of improper 
installation, operation, or maintenance. 
Because such damage is random in nature, 
each case must be analyzed separately to 
determine the appropriate repair proce- 



1 53 



NATIONAL BOARD INSPECTION CODE • PART 3 — REPAIRS AND ALTERATIONS 



dure, and the economics of repair versus 
replacement. 

c) Impervious graphite is a machinable mate- 
rial. Parts can be modified or repaired in the 
field, or in a repair shop. 

d) Machining operations may be handled with 
high-speed steel tools. Extensive machining 
requires tungsten carbide or diamond tool- 
ing. No cooling or flushing fluid is required, 
nor should either be used. 

e) Cleanliness is important. Dusty, dirty, and 
chemically contaminated surfaces prevent 
proper cement adhesion. Poor cement 
adhesion will result in a low strength joint 
or a joint which leaks. All surfaces should 
be neutralized to a pH of 7. Graphite parts 
should be cleaned and washed with ac- 
etone to remove all moisture. 

f) All damage should be examined and evalu- 
ated to determine the cause. Identification 
and elimination of the cause is essential in 
helping to prevent a recurrence. 

g) An acetone wash on the surface of the 
damaged part is useful in identifying the 
full extent of the cracks. The acetone will 
quickly evaporate from the surface, leaving 
the cracks damp and clearly visible. 



S3.5.2 



TYPICAL GRAPHITE FRACTURES 



S3.5.2.1 MAJOR FRACTURE 

An extensive fracture, such as shown in Figure 
S3. 5. 2. 1, is best repaired by completing the 
break and re-cementing the two pieces. Tem- 
porary steel banding around the circumference 
is a method of clamping the repair until the 
cement is cured. 



FIGURE S3.5.1-a 

Typical Tube-Tubesheet Joints 





S3.5.2.2 INTERMEDIATE FRACTURE 

The break is too minor to warrant completing 
the fracture. A pie-shaped cut may be made 
and the segment re-cemented in place. (See 
Figure S3. 5. 2. 2). 



S3.5.2.3 MINOR FRACTURE 

For minor fractures, such as those shown in 
Figure S3. 5. 2. 3, plug stitching can be used. 
The crack is removed by drilling and plugging 
a continuous chain of overlapping holes along 
the length and depth of fracture. 



1 54 



NATIONAL BOARD INSPECTION CODE • PART 3 — REPAIRS AND ALTERATIONS 



S3.5.3 GRAPHITE REPAIR BY PLUG 

STITCHING 
(SEE FIGURE S3.5.3) 

a) Plug stitching is a form of repair by material 
inlaying. In this case, the inlays are small 
cylindrical impervious graphite plugs. The 
crack or fracture is removed by drilling and 
plugging a continuous series of overlapping 
holes along its length and depth. 

b) Most plug stitching is done with 7/8 in. 
(22 mm) diameter plugs. The plugs are 
laid out along the fracture line on a pitch 
of 5/8 in. (1 6 mm) centers. The overlap of 
plug material is 1/4 in. (6 mm) along the 
fracture line. A number of plug sizes are 
available and are used in repair, and the 
amount of overlapping is proportional to 
their diameters. 



S3.5.3.1 PLUG STITCHING PROCEDURE 
(SEE FIGURE S3.5.3) 

The following procedure is defined for 7/8 in. 
(22 mm) diameter plugs (an undersized plug 
will allow the use of common size tooling). Di- 
mensions for other size plugs shall be adjusted 
proportionally to the diameter. 

a) Trace the line of fracture with acetone and 
mark its length and direction. 

b) Beyond the end points of the fracture (crack), 
one additional plug shall be installed. 

c) Starting 5/8 in. (16 mm) beyond the end 
point of the crack, mark drilling centers 
every 5/8 in. (1 6 mm) along its length. Make 
sure there is a plug to be installed outside 
both end points of the line of fracture. 

d) Drill a 1/4 in. (6 mm) pilot hole at each 
location. 

c) Redrill a 7/8 in. (22 mm) hole at every 
other pilot hole. Holes must be drilled 
the full depth of the crack. The depth and 
direction of the crack can be checked with 
acetone. 



FIGURE S3.5.3 



Step One 

Layout Hole Centers 

Pattern for 7/8" (22 mm) Diameter Plugs 



(16mm) (16mm) (16mm) (16mm) (16mm) (16mm) 




One additional hole location beyond the endpoints of the fracture 



Step Two 
Drill Pilot Holes 




1-'4" (6 mm) diameter pilot holes drilled at each location. 
The dashed lines represent whore the Iracture line existed. 



SteD Three 
Drill the First Set of Holes 




Drill every other hole to 7.'8" (?? mm) diameter 



Step Four 
Cement and Cure the First Set of Plugs 




Step Five 
Drill the Second Set o' Holes 




The second set of diameter holes is drilled between the installed plugs 
The cashed line represents where Ine fracture line existed. 



Step Six 
Plug St tch Repair Completed 




The dashed line represents wne'e the line existed. 

It has been comp : etely drilled out and replaced with cverlaoping 

graphite plugs The fracture no longer exists. 



1 57 



NATIONAL BOARD INSPECTION CODE • PART 3 — REPAIRS AND ALTERATIONS 



f) A 7/8 in. (22 mm) diameter reamer may be 
used to true the drilled holes. 

g) Dry fit a plug into the holes. There should be 
0.005 in. to 0.01 in. (.13 mm to .25 mm) 
clearance for the cement joint. At no time 
should there be a force fit of plugs into any 
drilled hole. Provisions shall be provided 
for venting trapped air. 

h) Sand the outside surface of the plugs. Thor- 
oughly clean all the surfaces of the repair, 
plugs, and drilled holes with acetone. 

i) Apply graphite cement to both plugs and 
holes. All surfaces of plugs and holes to be 
joined are to be wetted with cement. 

j) Insert the cemented plugs into the holes 
allowing 1/16 in. (1.5 mm) of the plug to 
extend beyond the surface of the graphite 
part. 

k) Cure the graphite cement according to the 
cement Manufacturer's instruction. 

I) At this point, half of the plug stitch repair 
is completed. A row of plugs has been 
installed with 1/4 in. (6 mm) pilot holes 
between them. 

m) Redrill the remaining pilot holes to 7/8 in. 
(22 mm) diameter. The drill will remove 
part of the plugs that were installed. It is 
important to have the plugs replace all of 
the fracture. If the new holes do not cut into 
the installed plugs, it will be necessary to 
repeat the procedure between these holes 
and plug locations to ensure that all of the 
crack has been repaired. The line of fracture 
is completely removed by the overlapping 
effect of the graphite plugs. 

n) After the second set of holes have been 
drilled, repeat the plug cementing proce- 
dures. 

o) Contour the plugs to provide a smooth 
transition into the adjoining surface area. 
The finished repair may be coated with a 
wash coat for appearance. 



S3.5.3.2 FIGURES — TYPICAL PLUG 
STITCHING PROCEDURE 
SEE FIGURE S3.5.3 

a) Step one: Layout hole centers. 

b) Step two: Drilling pilot holes. 

<:) Step three: Drilling the first set of holes. 

d) Step four: Cementing and curing the first 
set of plugs. 

e) Step five: Drilling the second set of holes. 

f) Step six: Plug stitching repair completed. 



S3.5.4 RE-IMPREGNATION OF 

GRAPHITE PARTS (TUBESHEETS, 
HEADS, AND BLOCKS) 

a) As a function of time, temperature, and 
chemical exposure, the resin used to 
impregnate graphite may shrink and/or 
degrade. As such, it is possible for voids 
to develop in impregnated graphite that 
has been in chemical service for a period 
of time. The resin loss can vary from slight 
to almost complete loss of impregnation. 
There is no practical way to determine the 
amount of resin remaining in the pores. 
However, a pressure test will determine if A08 
the graphite has continuous porosity. 

b) Re-impregnation of a graphite component 
may be used to reduce porosity in an exist- 
ing graphite component, which in turn will 
improve the performance and expected 
life of the existing graphite components. 
A written re-impregnation procedure ac- 
ceptable to the Inspector is required. The 
re-impregnation procedure shall include as 
a minimum: 

1) Decontamination and drying of the 
graphite component 

2) Subjecting the component to a vacuum 



1 5B 



NATIONAL BOARD INSPECTION CODE • PART 3 



REPAIRS AND ALTERATIONS 



3) Introducing resin under pressure 

4) Curing the resin at a specified tempera- 
ture and time 

5) Leak test 



S3.5.4.1 CONTROL OF IMPREGNATION 
MATERIAL 

a) Impregnation material shall be the same 
as that specified in the Re-impregnation 
Procedure. Each impregnation material 
shall be traceable by the name of its manu- 
facturer and the trade name or number of 
that manufacturer. 

b) The impregnation material manufacturer 
shall supply the Certificate Holder a Cer- 
tificate of Analysis for each material. It shall 
include the following: 

1) Impregnation material identification 

2) Batch number(s) 

3) Date of manufacture 

4) Shelf life 

5) Viscosity per ASTM D 2393 

6) Specific gravity 

c) Prior to re-impregnation, and at subse- 
quent intervals not to exceed 14 days, the 
Certificate Holder shall test each batch of 
impregnation material to assure that the 
characteristics of the material have not 
changed from values specified in the Re-im- 
pregnation Procedure. The values obtained 
for viscosity and specific gravity for the 
impregnation material shall be within the 
limits specified by the manufacturer and as 
listed in the Re-impregnation Procedure. 
The test values shall be made available to 
the Inspector. 



S3.5.4.2 FINISHING THE REPAIR 

a) The parts should be held in place to prevent 
movement while curing the cemented joint 
to achieve a proper repair. The repair firm 
should take care to ensure that the cement 
joint thickness is within the range recom- 
mended by the cement manufacturer. Care 
spent in precisely aligning the parts while 
clamping will avoid many finishing and 
machining operations later. Particular at- 
tention should be given to gasket and other 
bearing surfaces. 

b) Gasket and bearing surfaces may have to 
be machined, filed, or sanded before the 
job is completed. Gasket serrations must 
be clean and continuous. Serrations can be 
easily re-cut into graphite and any repair 
plugs that cross the gasket surface. 



1 59 



NATIONAL BOARD INSPECTION CODE • PART 3 — REPAIRS AND ALTERATIONS 



SUPPLEMENT 4 

REPAIR AND ALTERATION OF 
FIBER-REINFORCED 
THERMOSETTING PLASTIC 
PRESSURE EQUIPMENT 



S4.1 



SCOPE 



a) This supplement provides general require- 
ments that apply to repairs and alterations 
to fiber-reinforced pressure-retaining 
items. 

b) The letters "RP" shall be included on the 
"R" Certificate of Authorization for those 
organizations authorized to perform re- 
pairs/alterations of fiber-reinforced plastic 
pressure equipment. 



S4.2 



INSPECTOR QUALIFICATIONS 



The "R" Stamp holder's inspector shall have the 
following qualifications: 

a) No fewer than five years of current verifi- 
able documented experience in an occupa- 
tional function that has a direct relationship 
to Reinforced Thermoplastic (RTP) fabrica- 
tion and inspection, following customer or 
national standards, and be directly involved 
in the following activities: 

1) the development of plans, drawings, 
procedures, inspection requirements, 
acceptance criteria, and personnel 
qualification requirements; 

2) fabrication, construction, and supervi- 
sion of personnel in the production of 
assemblies or subassemblies; 



5) repairs of equipment or supervision of 
personnel performing repairs; 

6) preparation of written procedures for 
assembly, acceptance, nondestructive 
evaluation, or destructive tests; 

7) qualification of secondary bonders, 
laminalors, and welders to applicable 
codes, standards, or specifications; 

8) operation techniques or activities used 
to fulfill quality control requirements 
for RTP fabrication or assembly; and 

9) train the occupational skills of fabrica- 
tion or assembly of RTP equipment. 

b) The inspector shall meet the following vi- 
sual and educational requirements: 

1) be able to read a Jaeger Type No. 1 
standard chart at a distance of not less 
than 12 in. (.305 mm); 

2) be capable of distinguishing and dif- 
ferentiating contrast between colors; 

3) have visual acuity checked annually 
to assure natural or corrected near dis- 
tance vision; and 

4) be a high school graduate or hold a 
state or military approved high school 
equivalency diploma. 

c) The employer of the inspector shall certify 
that the employee complies with the above 
qualification requirements. 



S4.3 



TOOLS 



3) detection and measurement of non- 
conformities by application of visual 
or other nondestructive evaluation 
processes to written procedures; 

4) supervision of personnel engaged in 
material and component examination; 



The following tools may be required by the 
inspector: 

a) adequate lighting including overall lighting 
and a portable lamp for close inspections; 

b) handheld magnifying glass; 



i en 



NATIONAL BOARD INSPECTION CODE • PART 3 — REPAIRS AND ALTERATIONS 



SUPPLEMENTS 

GENERAL REQUIREMENTS FOR 
REPAIRS AND ALTERATIONS TO 
YANKEE DRYERS 



original code of construction. Yankee dryer 
pressure-retaining parts may include: 

1) shell 



S5.1 



SCOPE 



This supplement provides additional require- 
ments for repairs and alterations to Yankee 
dryer pressure-retaining components and 
shall be used in conjunction with inspection 
requirements identified in Part 2, Inspection 
Supplement 5. 



S5.2 EXAMINATIONS AND TEST 

METHODS 

In addition to the requirements of 4.4.1 and 
4.4.2, the following are recommended: 

a) Acoustic emission testing 

b) Metallographic examination when thermal 
damage is suspected due to operational or 
repair activities. 



S5.3 YANKEE DRYER REPAIR 

METHODS 



ire- 



This supplement provides additional requite 
ments for repair methods to yankce dryer pres- 
sure-retaining components and shall be used in 
conjunction with Section 2 thru 5 of this part, 
as appropriate. 



S5.3.1 REPLACEMENT PARTS FOR 

YANKEE DRYERS 

a) Yankee dryer replacement pressure-retain- 
ing parts shall be fabricated in accordance 
with the manufacturer's design and the 



2) heads 

3) center shaft, stay, or trunnion 

4) stay bars 

5) structural bolting 

6) journals 

b) Replacement of nonpressure-retaining 
parts, when different from the manufac- 
turer's design, shall be evaluated for any 
possible effect on the pressure-retaining 
parts. 



S5.4 REPAIR GUIDE FOR YANKEE 

DRYERS 

a) Welding or brazing shall not be used on 
any Yankee dryer pressure-retaining com- 
ponent manufactured from cast iron. The 
Manufacturer's Data Report shall be care- 
fully reviewed to determine the material of 
construction of each Yankee dryer compo- 
nent such as shell, heads, and journals. 

b) Structural deterioration or damage caused 
by corrosion, thinning, or cracking shall 
not be repaired until their extent has been 
determined by suitable nondestructive ex- 
amination. 

c) The user shall have a plan covering the 
scope of the repair. The plan shall ensure 
that the work involved is compatible with 
Ihe original design specification and good 
engineering practices. 

d) All repair work shall be documented. 



1 B 1 



NATIONAL BOARD INSPECTION CODE • PART 3 



REPAIRS AND ALTERATIONS 



S5.5 PROCEDU RES THAT DO NOT 

REQUIRE STAMPING OR 

NAMEPLATE ATTACHMENT 

All repair procedures, shall be acceptable to the 
Inspector, and when verified by the owner-user 
to not affect pressure-retaining capability of the 
Yankee dryer, do not require stamping or name- 
plate attachment. Examples of repairs are: 

a) Grinding and machining: 

1) removal of shell overhung flange 

2) removing bolt-stop ring for test 
specimens 

A07 3) head/shell joint corrosion removal 

4) journal grinding 

5) shell surface grinding (crowning) 

6) crack removal 

7) head flange OD reduction 

8) back spot facing of flange surfaces 
(head, shell, journal) 

b) Metallizing (full face, spot, edge): 

1 ) applying a metallized coating 

2) grinding of a metallized coating 

A07 c) Fpoxy (sealant) repair of steam leaks at 
bolted joints (using fittings and pumping 
bolts) and epoxy filling of surface imperfec- 
tion 

d) Installation of spoiler bars 

e) Maintain/repair/replace internal conden- 
sate removal system 

f) Driven plug repair when completed as 
described in S5.6.3. 

A08 g) Threaded plug repair when completed as 
described in S5.6.4. 



S5.6 DAMAGE REPAIR 



S5.6.1 REPAIR OF LOCAL THINNING 

a) A Local Thin Area (LTA) may develop in a 
pressure-retaining part or may result from 
the original casting process, lnservice thin 
areas may result from mechanical wear, 
erosion-corrosion caused by steam and 
condensate flow, corrosion, impact dam- 
age, or grinding for the removal of material 
flaws. 

b) Evaluation of thinning for repair shall 
consider the unique design and loading 
characteristics of the Yankee dryer. Local 
thin areas are often analyzed as specific 
cases by the finite element method. 

1 ) When a LTA is evaluated by finite ele- 
ment method, analysis should consider 
the location of the thin area and ac- 
count for strength provided by the ves- 
sel center shaft and heads in addition 
to the strength provided by the shell 
alone. Such structural analysis should 
consider all relevant loads to ensure 
safe operation of the shell according 
to the De-rate Curve, or other pres- 
sure-retaining parts as indicated on the 
original Manufacturer's Data Report. 

2) Following evaluation and determina- 
tion of maximum allowable operating 
parameters, a LTA can be coated or 
filled to prevent further wear or deterio- 
ration. Grooves and gouges should al- 
ways be lightly ground to remove sharp 
notches and edges. Welding or brazing 
repairs are NOT permitted on cast-iron 
pressure-retaining components. 

3) Where the LTA is of sufficient size to 
cause a reduction in maximum allow- 
able operating parameters according to 
the De-rate Curve, an R-2 Form shall be 
submitted. 

4) Depending upon the cause of the LTA, 
further monitoring may be necessary 



1 S2 



NATIDNAL BOARD INSPECTION CODE • PART 3 



REPAIRS AND ALTERATIONS 



to ensure deterioration has been ar- 
rested. 

5) Inspection data, including all thickness 
readings and corresponding locations 
used to determine the minimum and av- 
erage thicknesses, and the accompany- 
ing stress analysis, should be included 
in the documentation and retained for 
the life of the vessel. 



S5.6.2 TREATMENT OF CRACK-LIKE 

FLAWS 

a) Crack-like flaws are planar flaws that are 
predominantly characterized by a length 
and depth with a sharp root radius. They 
may either be embedded or surface break- 
ing. In some cases it may be advisable to 
treat volumetric flaws, such as aligned po- 
rosity, inclusions, and laps, as planar flaws, 
particularly when such volumetric flaws 
may contain microcracks at the root. 

1) Knowledge of local stress level and 
classification, and of flaw origin, type, 
size, location, and angle relative to the 
principal stress direction is essential in 
making determinations regarding re- 
mediation. It is also important to know 
whether the crack is active. Acoustic 
Emissions Testing can be used to deter- 
mine if the crack is active. Various other 
A07 methods of nondestructive examina- 

tion should be employed to determine 
crack length and depth. Ultrasonics 
is the recommended sizing technique 
for depth and inclination of crack-like 
flaws. Magnetic particle, specifically 
the wet fluorescent technique, and dye 
penetrant methods are applicable in 
determining the length of a surface flaw. 
Radiographic methods may also be use- 
ful. Metallographic analysis is crucial in 
differentiating between original casting 
flaws and cracks. 

A08 2) Evaluation of crack-like flaws, that have 
been determined to be cracks, is most 
often accomplished through removal 



via grinding or machining. Because 
cast iron is categorized as a brittle ma- 
terial, this is the conservative approach 
regarding crack-like flaws. Welding or 
brazing repairs are not permitted for A07 
cast-iron parts. Metalstitching is permit- A08 
ted as a repair. However this method of 
repair requires evaluation as to whether 
a reduction in allowable operating con- 
ditions is required. This evaluation shall 
be performed by the manufacturer or by 
another qualified source acceptable to 
the Inspector. 

3) Crack-like flaws that have been identi- 
fied as cracks, but which developed 
from normal service exposure or 
excessive operating conditions, shall 
be remediated by appropriate means 
regardless of location. 

4) Crack-like flaws that have been identi- 
fied as cracks that developed through 
non-standard load events, such as by 
water hoses from operation or fi relight- 
ing or mechanical damage, shall be 
remediated if in the shell. Cracks in 
other pressure-retaining parts, shall be 
analyzed, documented, and monitored 
to ensure their presence will not be, 
or have not been, affected by current 
operating conditions. 

5) Crack-like flaws that are not identified 
as cracks, but existed in the original 
material, i.e., material flaws, shall be 
analyzed, documented, and monitored 
to ensure their presence will not be, 
or have not been, affected by current 
operating conditions. 

b) All documents pertaining to the crack-like 
flaw assessment shall be retained for the life 
of the vessel. Documentation should ad- 
dress the engineering principles employed, 
including stress analysis methods and flaw 
sizing, the source of all material data used, 
identification of any potential material 
property degradation mechanisms and the 
associated influence on the propagation of 



1 S3 



NATIONAL BDARD INSPECTION CODE • PART 3 



REPAIRS AND ALTERATIONS 



flaw, and the criteria applied to the assess- 
ment procedures. 



S5.6.3 



DRIVEN PLUG REPAIR 



Shell surface imperfections should be repaired 
with smooth, driven plugs as described in ASME 
Section VIII, Div. 1, UCI-78, with the following 
additional requirements: 

a) Maximum plug length (depth) shall be 
limited to 20% of shell effective thickness, 
and plug diameter shall not exceed the plug 
length (depth). 

b) Total surface area of plugs shall not exceed 
4 sq. in. in an 8 in. diameter circle (2580 
sq. mm in a 200 mm diameter circle). 

c) Average number of shell plugs shall not 
exceed 1 plug per 1 sq. ft. (1 plug per 0.1 
sq. m) of the surface. 

d) The land distance between edges of plugs 
shall be at least equal to the diameter of the 
larger plug. 

e) The plug material shall conform in all re- 
spects to the material specification of the 
base material. 

f) The installed plug shall have an interference 
fit. The average hole diameter is determined 
after the plug hole is drilled or reamed. The 
maximum plug diameter shall not exceed 
1 .01 2 times the average hole diameter. This 
provides an interference fit while minimiz- 
ing the residual stresses. 

g) All plug repair work shall be documented 
in the form of a plug repair map or other 
suitable method of recording and retained 
in the dryer's permanent file. 



A08 S5.6.4 



THREADED PLUG REPAIR 



Casting defects, leaks and local thin areas 
should be repaired with threaded plugs as 
described in ASME Section VIII, Division 1, 
UCI-78 with the additional requirement that a 



threaded plug shall not be used in an area sub- 
ject to dynamic loading (e.g. , Yankee dryer shell) 
as determined by the manufactuler or another 
qualified source acceptable to the Inspector. 

S5.7 ALTERATIONS TO YANKEE 

DRYERS 



S5.7.1 SCOPE 

This supplement provides additional require- 
ments for alterations to Yankee dryer pressure- 
retaining components and shall be used in 
conjunction with Sections 2 thru 5 of this Part, 
as appropriate. 



S5.7.2 



ALTERATION TYPES 



b) 



Any change in the Yankee dryer (shell, 
heads, center shaft, fasteners), as described 
on the original Manufacturer's Data Report, 
which affects the pressure-retaining capa- 
bility, shall be considered an alteration. 
Examples of alterations are: 

1) Drilling/enlarging of bolt holes in cast- 
ings for larger diameter bolts; 

2) Replacement of structural bolts differing 
in size, material, or design, from those 
described on the Manufacturer's Data 
Report; 

3) Removal of shell overhung flange; 

4) Journal machining; 

5) Head flange outside diameter reduc- 
tion; 

6) Machining of head flange or shell flange 
surface to remove corrosion; and 

7) Operating above the nameplate tem- 
perature. 

Alteration procedures shall be written, 
reviewed, approved, and accepted by the 
Inspector prior to the start of work. 



1 B4 



NATIONAL BOARD INSPECTION CODE • PART 3 — REPAIRS AND ALTERATIONS 



SUPPLEMENT 6 

REPAIR, ALTERATION, AND 
MODIFICATION OF DOT 

TRANSPORT TANKS 



S6.0 GENERAL REQUIREMENTS 



S6.1 SCOPE 

A07 This supplement provides general requirements 
that apply to the repairs, alterations, or modi- 
fications to DOT Transport Tanks used for the 
transportation of dangerous goods via highway, 
rail, air, or water. 



A07 S6.2 



CONSTRUCTION STANDARDS 



A07 When the standard governing the original con- 
struction is the ASME code or other regulations 
of the Competent Authority, repairs, altera- 
tions, or modifications shall conform, insofar 
as possible, to the edition of the construction 
standard or specification most applicable to the 
work. Where this is not possible or practical, 
it is permissible to use other codes, standards 
or specifications, including the ASME code 
provided the "TR" Certificate Holder has the 
concurrence of the inspector or the Competent 
Authority. 



A07 S6.3 



ACCREDITATION 



A07 Organizations performing repairs, alterations, or 
modifications shall be accredited as in accor- 
dance with the National Board "TR" Program. 



A07 S6.4 



MATERIALS 



A07 The materials used in making repairs, altera- 
tions, or modifications shall conform to the 
original code of construction including the 
material specification requirements. Carbon 



or alloy steel having a carbon content of more A07 
than 0.35% (0.30% for ton tanks) shall not be 
welded unless permitted by the original code 
of construction. The "TR" Certificate Holder is 
responsible for verifying identification of exist- 
ing materials from original data, drawings, or 
unit records and identification of the material 
to be installed. 



S6.5 



REPLACEMENT PARTS 



A07 



a) Replacement parts that will be subject to A07 
internal or external pressure that consist 

of new material which may be formed to 
the required shape by spinning, forging, 
die forming, and on which no fabrication 
welding is performed shall be supplied 
as material. Such parts shall be marked 
with the material and part identification 
and the name or trademark of the parts 
manufactured. In lieu of full identification 
marking on the material or part, the part 
manufacture may use a coded marking 
system traceable to the original marking. 
Such markings shall be considered as the 
part manufacture's certification that the 
part complies with the original code of 
construction. Examples include seamless or 
welded tube or pipe, forged nozzles, heads 
or subassemblies attached mechanically. 

b) Replacement parts that will be subject to A07 
internal or external pressure that are preas- 
sembled by attachment welds shall have the 
welding performed in accordance with the 
original code of construction. This certifi- 
cate shall be supplied in the form of a bill 

of material or drawings with statement of 
certification. 

c) Replacement parts subject to internal or A07 
external pressure fabricated by welding 
that require shop inspection by an Autho- 
rized Inspector shall be fabricated by an 
organization having an appropriate ASME 
Certificate of Authorization. The item shall 

be inspected and stamped as required by 



1 B5 



NATIONAL BOARD INSPECTION CODE • PART 3 — REPAIRS AND ALTERATIONS 



the applicable section of the ASME Code 
and DOT specification requirements. A 
completed ASMF Manufacturer's Partial 
Data Report shall be supplied by the manu- 
facturer. 

d) When the original code of construction is 
other than ASME, replacement parts subject 
to internal or external pressure fabricated 
by welding shall be manufactured by an 
organization certified as required by the 
original code of construction. The item shall 
be inspected and stamped as required by 
the original code of construction. Certifi- 
cation to the original code of construction 
as required by the original code of con- 
struction or equivalent shall be supplied 
with the item. When this is not possible or 
practicable the organization fabricating the 
part may have a National Board Certificate 
of Authorization. Replacement parts shall 
be documented on FormTR-1 and the "TR" 
stamp applied as described in S6.1 4. 



S6.6 



AUTHORIZATION 



The Inspector's written authorization to per- 
form a repair, alteration, or modification shall 
be obtained prior to initiation of the repair or 
modification to a transport tank . 



S6.7 



INSPECTION 



Inspection and certification shall be made by an 
Inspector employed by one of the following: 

a) An organization authorized and recognized 
by the Competent Authority. 

b) The Authorized Inspection Agency of the 
"TR" Certificate Holder making the repair 
or modification. 



S6.7.1 INSPECTOR DUTIES FOR 

REPAIRS, ALTERATIONS, AND 
MODIFICATIONS 



A07 



a) Repair Organizations that possess the Na- 
tional Board "TR" Certificate of Authoriza- 
tion and DOT's Cargo Tank Registration 
(CTR) number when applicable shall use 
inspection services of a Registered Inspec- 
tor while performing repairs, or Modifica- 
tions of Transport Tanks. The Registered 
Inspector must have satisfied the following 
requirements: 

1) Has satisfied DOT requirements as a 
Registered Inspector. 

2) Has successfully completed the Na- 
tional Boards' Web-based training 
program for Registered Inspectors and 
issued a National Board Certificate of 
Completion. 

3) Has received authorization from DOT 
as a Registered Inspector. 

4) Has been registered by DOT for the 
Classification(s) of Transport Tanks to 
be inspected. 

b) Inspectors performing repair or modifica- A07 
tion inspections under the requirements of 
this supplement shall satisfy the require- 
ments of S6.7.1 to be authorized to sign 

the Form TR-1, Repairs or Modifications 
and Form TR-2, Supplemental Form. 

c) For repairs and modifications of transport A07 
tanks, the duties of the Registered Inspector 

are detailed in Part 2, S6.10 thru S6.15, as 
required by the Competent Authority. 

d) In addition, the duties of the Registered A07 
Inspector are summarized below: 

1) Verify the organization performing 
the repair or modification activity is 
properly accredited and in possession 



1 B6 



NATIONAL BOARD INSPECTION CODE • PART 3 



REPAIRS AND ALTERATIONS 



of a current Certificate of Authorization 
to apply the "TR" Stamp issued by the 
National Board and is working to an 
approved Quality Control System. 

A07 2) Verify that the design, if required, for the 
modification of the vessel is approved 
by a Design Certifying Engineer, or 
Designated Approval Agency or other 
applicable individual. 

A07 3) Verify the materials to be used to make 
the repair or modification are approved 
for use and comply with applicable 
Code requirements. 

A07 4) Verify the welding procedures and 
welders or welding operators are prop- 
erly qualified. 

A07 5) Verify that all heat treatments, if re- 
quired, including PWHT have been 
performed in accordance with the ap- 
plicable standards and that the results 
are acceptable. 

A07 6) Verify that all NDE, impact tests, and 
other tests have been performed when 
required, and that the results are ac- 
ceptable. 

A07 7) Make a visual inspection of the work 
performed to confirm there are no vis- 
ible defects or deviations from Code 
requirements. 

A07 8) Perform external and internal visual in- 
spections, if the vessel is equipped with 
a manway, and witness the hydrostatic 
or pneumatic pressure test and/or leak 
tightness test when they are required. 

A07 9) Verify the correct nameplate is properly 
attached to the vessel and that the cur- 
rent test and inspection markings are 
properly attached and displayed on the 
proper vessel. 

A07 1 0) Sign the Form TR-1 and as appropriate 
TR-2. 



S6.8 



WELDING 



A07 



b) 



Welding shall be performed in accordance A07 
with the requirements of the original code 
of construction used for the fabrication of 
the pressure vessel. For hydrogen control 
when low alloy steel filler metals are used, 
the filler metal classification shall include 
an H4 supplemental diffusible hydrogen 
designator (maximum 4 ml [H2]/1 00 g de- 
posited metal) for each of the following: 

1 ) electrodes for shielded metal arc weld- A07 
ing conforming to SFA-5.5 

2) electrodes and fluxes for submerged arc A07 
welding conforming to SFA-5.26 

3) electrodes and rods for gas shielded A07 
metal arc welding conforming to SFA- 
5.28 

4) electrodes for flux cored arc welding A07 
conforming to SFA 5.29. 

Practices used for controlling storage and A07 
exposure of filler metals shall be those 
developed by the "TR" Certificate Holder 
or those recommended by the filler metal 
manufacturer. 



S6.8.1 WELDING PROCEDURE 

SPECIFICATION 



A07 



Welding shall be performed in accordance A07 
with a Welding Procedure Specification (WPS) 
qualified in accordance with the original code 
of construction. When this is not possible or 
practicable, the WPS may be qualified in ac- 
cordance with Section IX of the ASMF Code. 



S6.8.2 STANDARD WELDING 

PROCEDURE SPECIFICATIONS 



A07 



A "TR" Certificate holder may use one or 
more applicable Standard Welding Procedure 



l by 



NATIONAL BOARD INSPECTION CODE • PART 3 



REPAIRS AND ALTERATIONS 



Specifications shown in 2.3 without supporting 
Procedure Qualification Records (PQRs) since 
SWPS are pre-qualified and the PQR will not 
be supplied. 



Certificate Holder may keep a record of the 
welded joints and the welders or welding op- 
erators used in making the joint. 



A07 S6.8.3 



S6.8.6 



WELDERS' CONTINUITY 



PERFORMANCE 

QUALIFICATION 



A07 



A07 Welders or welding operators shall be qualified 
for the welding processes that are used. Such 
qualification shall be in accordance with the 
requirements of the original code of construc- 
tion or Section IX of the ASME Code. Use of 
Standard Welding Procedures Specification 
shown in 2.3 is permitted for performance 
qualification testing. 



A07 S6.8.4 



WELDING RECORDS 



A07 The "TR" Certificate Holder shall maintain a 
record of the results obtained in welding pro- 
cedure qualification, except for those qualifi- 
cations for which the provisions of S6.8.2 are 
used and of the results obtained in welding 
performance qualifications. These records shall 
be certified by the "TR" Certificate Holder and 
shall be available to the inspector. 



A07 S6.8.5 WELDERS' IDENTIFICATION 

A07 The "TR" Certificate Holder shall establish a 
system for the assignment of a unique identifi- 
cation mark to each welder/welding operator 
qualified in accordance with the requirements 
of the NBIC. The "TR" Certificate Holder shall 
also establish a written procedure whereby 
all welded joints can be identified as to the 
welder or welding operator who made them. 
This procedure shall use one or more of the 
following methods and be acceptable to the 
Inspector. The welder's or welding operator's 
identification mark may be stamped (low stress 
stamp) adjacent to all welded joints made by 
the individual or, in lieu of stamping, the "TR" 



The performance qualification of a welder or 
welding operator shall be affected when one 
of the following conditions occurs: 

a) When the welder or welding operator has A07 
not welded using a specific process during 

a period of six months or more, their quali- 
fications for that process shall expire. 

b) When there is specific reason to question 
their ability to make welds that meet the A07 
specification, the qualification which sup- 
ports the welding that is being performed 
shall be revoked. All other qualifications 

not questioned remain in effect. 



S6.9 HEAT TREATMENT 



S6.9.1 PREHEATING 



A07 



Preheating may be employed during welding 
to assist in completion of the welded joint (see 
2.5.1). The need for and the temperature of 
preheat are dependent on a number of factors 
such as chemical analysis, degree of restraint of 
the items being joined, material thickness, and 
mechanical properties of the base metals being 
joined. The Welding Procedure Specification 
for the material being welded shall specify the 
preheat temperature requirements. 



S6.9.2 POSTWELD HEAT TREATMENT 

Postweld heat treatment may be performed as 
required by the original code of construction 
in accordance with a written procedure. The 



1 BS 



NATIONAL BOARD INSPECTION CODE • PART 3 



REPAIRS AND ALTERATIONS 



procedure shall contain the parameters for 
postweld heat treatment. Local PWHT that is 
not specified by the original code of construc- 
tion may be performed in accordance with an 
Alternative Postweld Heat Treatment Method 
described in 2.5.3 with acceptance by the 
Inspector and required by the Competent Au- 
thority. 



A07 S6.9.3 ALTERNATIVES TO POSTWELD 

HEAT TREATMENT 

A07 a) Under certain conditions, postweld heat 
treatment in accordance with the original 
code of construction may be inadvisable 
or impractical. In such instances, alterna- 
tive methods of postweld heat treatment or 
special welding methods acceptable to the 
Inspector and Competent Authority may be 
used. 

A07 b) When the standard governing the origi- 
nal construction is the Code of Federal 
regulation for DOT/MC 331 cargo tanks 
for propane, butane, anhydrous ammonia, 
and other DOT permitted commodities, 
and the tanks are made to the ASME Code, 
Section VIII, Division 1, Part UHT, repairs, 
alterations, or modifications shall conform 
insofar as possible, to the edition of the 
construction standard or specification most 
applicable to the work. Where this is not 
possible or practicable, it is permissible to 
use other codes, standards, or specifications 
provided the "TR" Certificate Holder has 
the concurrence of the DOT. Shells and 
heads of MC 331 cargo tanks were made 
from quenched and tempered alloy steel 
plate, SA517, Grade E (originally Code 
Case 1298) and Grade F (originally Code 
Case 1204) prior to 1994. 

A07 c) The 1994 ASME Code Addenda revised 
UHT-5(b) to permit the joining of UHT 
materials to UCS or UHA materials in head 
and shell sections. Propane, butane, and 
anhydrous ammonia are the most common 



transported commodities and the shipper 
is required by DOT to comply with cer- 
tain composition limitations. Propane and 
butane transported must have sufficiently 
low hydrogen sulfide content so as not to 
exceed the limitations for classification one 
of the ASTM D1 838-74 copper strip test, 
and the anhydrous ammonia transported 
must be inhibited with a minimum water 
content of 0.2% by weight. In addition, 
such cargo tanks made for propane, butane, 
and anhydrous ammonia service must be 
postweld heat treated, unless specifically 
exempted by a DOT special permit that 
exempts PWHT. 



S6.10 NONDESTRUCTIVE 

EXAMINATION 



A07 



a) The nondestructive examination (NDE) A07 
requirements, including technique, extent 

of coverage, procedures, personnel quali- 
fication, and acceptance criteria, shall be 
in accordance with the original code of 
construction used for the pressure vessel, 
and repairs, alterations, and modifications 
shall be subjected to the same nonde- 
structive examination requirements as the 
original welds. Where this is not possible 
or practicable, alternative NDE methods 
acceptable to the Inspector and the Com- 
petent Authority may be used on a case by 
case basis. 

b) NDE personnel shall be qualified and certi- A07 
fied in accordance with the requirements 

of the original code of construction. When 
this is not possible or practicable, NDE 
personnel may be qualified and certified 
in accordance with their employer's writ- 
ten practice. ASNT SNT-TC-1A, Recom- 
mended Practice for Nondestructive Testing 
Personnel Qualification and Certification, 
or ACCP-189, Standard for Qualification 
and Certification of Nondestructive Test- 
ing Personnel, may be used to fulfill the 
examination and demonstration require- 



1 B9 



NATIONAL BOARD INSPECTION CODE • PART 3 



REPAIRS AND ALTERATIONS 



merits of SNT-TC-1A and the employer's 
written practice. Provisions for qualification 
and certification of NDE personnel shall 
be described in theTR Certificate Holder's 
written quality system. 



A07S6.11 



COATINGS AND LININGS 



When coatings or linings are to be inspected, 
such inspections shall be done in accordance 
with the Structural Steel Painting Council, SSPC 
publication, #91 -1 2, Coating and Lining Inspec- 
tion Manual. 



A07 S6.12 MEASUREMENT, EXAMINATION, 

AND TEST EQUIPMENT 

There shall be a system for calibration of pres- 
sure gages, measurement, examination, and test 
equipment. This system shall be documented. 



A07S6.13 



ACCEPTANCE INSPECTION 



The Inspector making the acceptance inspec- 
tion shall be the same Inspector who autho- 
rized the repairs, alterations, or modifications. 
Where this is not possible or practical, another 
Inspector may perform the acceptance inspec- 
tion; however, in all cases, the Inspector who 
performs the acceptance inspection shall be 
an employee of the same organization as the 
Inspector who authorized the repairs, altera- 
tions, or modifications. 



Certificate Holder responsible for the repair or 
the construction portion of the modification/ 
alteration shall apply the stamping. For a re- 
rating where no physical changes arc made to 
the pressure-retaining item, the "TR" Certificate 
Holder responsible for the design shall apply 
the stamping. Requirements for stamping and 
nameplate information are shown in Section 
5 of this part. 



S6.14.1 REMOVAL OF ORIGINAL 

STAMPING OR NAMEPLATE 



A07 



If it becomes necessary to remove the original 
stamping, the Inspector shall, subject to the 
approval of the Competent Authority, witness 
the making of a facsimile of the stamping, 
the obliteration of the old stamping, and the 
transfer of the stamping. When the stamping 
is on a nameplate, the Inspector shall witness 
the transfer of the nameplate to the new loca- 
tion. Any relocation shall be described on the 
applicable NBIC TR Form. The restamping or 
replacement of a code symbol stamp shall be 
performed only as permitted by the governing 
code of construction. 



S6.15 



"TR" FORMS 



A08 



A07 



S6.15.1 REGISTRATION OF "TR" FORMS A07 

Organizations performing repairs, alterations, 
or modifications under the "TR" program must 
register such repairs, alterations, or modifica- 
tions with the National Board. 



A07S6.14 



STAMPING 



The stamping of or attaching of a nameplate to 
a pressure-retaining item shall indicate that the 
work was performed in accordance with the 
requirements of this Code and any requirements 
of the Competent Authority. Such stamping or 
attaching of a nameplate shall be done only 
with the knowledge and authorization of the 
Inspector and Competent Authority. The "TR" 



S6.15.2 FORM 'TR" LOG 

The "TR" Certificate Holder shall maintain a 
single, sequential log of "TR"; form numbers 
assigned for NBIC forms (i.e., TR-1) that are 
registered with the National Board. 



A07 



1 9D 



NATIONAL BOARD INSPECTION CODE • PART 3 



REPAIRS AND ALTERATIONS 



A07S6.16 ADDITIONAL REQUIREMENTS 

FOR REPAIRS, ALTERATIONS, 
OR MODIFICATIONS 



A07S6.16.1 SCOPE 

This section provides additional requirements 
for repairs, alterations, or modifications to 
pressure-retaining items and shall be used in 
conjunction with this section. 



A07 S6.1 6.2 REPAIRS OF DEFECTS 

Before a repair is made to a defect in a welded 
joint or base metal, care should be taken to 
investigate its cause and to determine its extent 
and likelihood of recurrence. This information 
shall be made available to the Inspector. 



A07S6.16.3 MODIFICATIONS 

All modifications to the pressure-retaining item 
shall meet the requirements of this section. 



A07S6.16.4 DRAWINGS 

Drawings or instructions shall be prepared to 
describe the repair, alterations, or modification. 
Drawings shall include sufficient information 
to satisfactorily perform the activity. 



A07S6.16.5 AUTHORIZATION 

Repairs, alterations, or modifications to pres- 
sure vessel shall not be initiated without the 
authorization of the Inspector, who shall de- 
termine that the repair methods are acceptable 
and subject to acceptance of the Competent 
Authority. 



S6.17 



EXAMINATION AND TEST 



A07 



The following requirements shall apply to all 
repairs to pressure-retaining items: 

a) The integrity of repairs and replacement 
parts used in repairs, alterations, or modi- 
fications shall be verified by examination 
and test. 

b) The "TR" Certificate Holder is responsible 
for all activities relating to examination 
and test of repair, alterations, or modifica- 
tions. 

c) Examination and tests to be used shall be 
subject to acceptance of the Inspector and 
the Competent Authority. 



S6.17.1 METHODS A07 

One or a combination of the following exami- 
nation and methods shall be applied to pres- 
sure-retaining items with the concurrence of the 
Inspector and the Competent Authority. 

a) Liquid Pressure Test A07 

Pressure testing of repairs shall meet the 
following requirements: 

1) Pressure tests shall be conducted us- A07 
ing water or other suitable liquid. The 
test pressure shall be the minimum 
required to verify the leak tightness 
integrity of the repair, but not more 
than 150% of the maximum allowable 
working pressure (MAWP) stamped 
on the pressure-retaining item, as ad- 
justed for temperature. When original 
test pressure included consideration of 
corrosion allowance, the test pressure 
may be further adjusted based on the 
remaining corrosion allowance. 



1 9 i 



NATIONAL BOARD INSPECTION CODE • PART 3 — REPAIRS AND ALTERATIONS 



A07 2) During a pressure test where the test 
pressure will exceed 90% of the set 
pressure of the pressure relief device, 
the device shall be removed when- 
ever possible. If not possible, a test 
gag should be used using the valve 
manufacturer's instructions and recom- 
mendations. 

A07 3) Hold time for the pressure test shall be 
a minimum of 10 minutes prior to ex- 
amination by the Inspector. Where the 
test pressure exceeds the MAWP of the 
item, the test pressure shall be reduced 
to the MAWP for close examination by 
the Inspector. Hold time for close ex- 
amination shall be as necessary for the 
Inspector to conduct the examination. 

A07 b) Pneumatic Test 

A pneumatic test may be conducted. Con- 
currence of the owner shall be obtained 
in addition to that of the Inspector and the 
Competent Authority where required. The 
test pressure shall be the minimum required 
to verify leak tightness integrity of the repair, 
but shall not exceed the maximum pneu- 
matic test pressure of the original code of 
construction. Precautionary requirements 
of the original code of construction shall 
be followed. 

A07 c) Nondestructive Examination 

Nondestructive examination (NDE) may be 
conducted. NDE methods shall be suitable 
for providing meaningful results to verify 
the integrity of the repair. 



A07S6.17.2 STAMPING 

Pressure vessels repaired in accordance with 
the NBIC shall be stamped as required by Sec- 
tion 5 of this part. 



A07S6.17.3 DOCUMENTATION 

Repairs, alterations, or modifications that have 
been performed in accordance with the NBIC 



shall be documented on Form TR-1 , Report of 
Repair, Alteration, or Modification, as shown 
in Section 5 of this part. Form TR-2, Report 
Supplementary Sheet, shall be used to record 
additional data when space is insufficient on 
Form TR-1 . 



S6.18 



PREPARATION OF TR FORMS 



A07 



Preparation of "TR" Forms shall be the responsi- 
bility of the "TR" Certificate Holder performing 
the repairs, alterations, or modifications. An 
Inspector shall indicate acceptance by signing 
the appropriate "TR" form. 



S6.18.1 DISTRIBUTION 



A07 



a) Legible copies of the completed Form TR-1 
together with attachments shall be distrib- 
uted to the owner or user, the Inspector, 
and the Competent Authority, as required, 
and the Authorized Inspection Agency re- 
sponsible for the inspection. 

b) Distribution of the Form TR-1 and attach- 
ments shall be the responsibility of the 
organization performing the repair. 



S6.18.2 REGISTRATION A07 

Form TR-1 and TR-2 shall be registered with 
the National Board. 



S6.19 REPAIRS, ALTERATIONS, OR 

MODIFICATION REPORTS 



A07 



a) If repairs, alterations, or modifications are 
performed on a Transport Tank, i.e., cargo 
tank, portable tank, or ton tank, the Owner 
or User shall have the activity performed 
by a Repair Organization that has a valid 
"TR" Certificate of Authorization issued by 
the National Board. 

b) The repair, alteration, or modification shall 
be recorded on the Form TR-1 . If additional 



1 92 



NATIONAL BOARD INSPECTION CODE • PART 3 



REPAIRS AND ALTERATIONS 



spare is needed to properly record the re- 
pair, alteration, or modification, FormTR-2 
shall be used. 

c) It is the responsibility of the "TR" Symbol 
Stamp Holder to prepare, distribute, and 
maintain the Form TR-1 and, if required, 
FormTR-2. The Form(s) shall bedistributed 
as follows: 

1) Owner-User; 

2) Registered Inspector; 

3) Competent Authority (DOT); and 

4) National Board. 

d) The Form TR-1 shall be signed by a Regis- 
tered Inspector as defined in S6.7.1 . 



A07 S6.19.1 REGISTRATION OF FORM TR-1 

AND FORMTR-2 

a) It is required by DOT that the Form TR-1 
and, if applicable, FormTR-2 be registered 
with the National Board. 

b) The repair organization shall maintain a 
sequential Form "TR" Log that shall identify 
the following: 

1 ) Form number assigned for Form TR-1 ; 

2) Identify if the activity was a repair, al- 
teration, or modification; and 

3) Date sent to the National Board. 



A07 S6.19.2 GENERAL REQUIREMENTS "TR" 

STAMPING AND NAMEPLATES 

The holder of a "TR" Certificate of Authorization 
is required to affix a stamping or nameplate on 
the Transport Tank that indicates, as appropri- 
ate, that the repair, alteration, or modification 



has been performed in accordance with the 
requirements of this supplement of the NBIC 
and the additional requirements of the code 
of construction. The stamping or nameplate 
information shall satisfy the requirements of 
(a) thru (g) below: 

a) The required data shall be in characters at 
least 4 mm (5/32 in.) high; 

b) The markings may be produced by casting, 
etching, embossing, debossing, stamping, 
or engraving; 

c) The selected method shall not result in any 
harmful contamination or sharp disconti- 
nuities to the pressure-retaining boundary 
of the Transport Tank; 

d) Stamping directly on the Transport Tank, 
when used, shall be done with blunt-nose 
continuous or blunt-nose interrupted dot 
die stamps. If direct stamping would be 
detrimental to the item, required markings 
may appear on a nameplate affixed to the 
Transport Tank; 

e) The "TR" Certificate Holder shall use its 
full name as shown on the Certificate of 
Authorization or an abbreviation accept- 
able to the National Board; 

f) The stamping when directly on the item or 
when a nameplate is used shall be applied 
adjacent to the original manufacturer's 
stamping or nameplate. A single repair, 
alteration, or modification stamping or 
nameplate may be used for more than one 
repair to a Transport Tank, provided the 
repair, alteration, or modification activity is 
carried out by the same certificate holder; 

g) The date of each repair, alteration, or 
modification corresponding with the date 
on the Form TR-1 shall be stamped on the 
nameplate. 



1 93 



NATIONAL BOARD INSPECTION CDDE • PART 3 — REPAIRS AND ALTERATIONS 

A07 S6.19.3 STAMPING OF THE "TR" 
SYMBOL 

All repairs, alterations, and modifications, after 
acceptance by the Registered Inspector, shall 
have the "TR" Symbol affixed to the stamping 
or the nameplate. 



1 94 



NATIONAL BOARD INSPECTION CODE • PART 3 — REPAIRS AND ALTERATIONS 



SUPPLEMENT 7 

REQUIREMENTS FOR REPAIRS 
TO PRESSURE RELIEF DEVICES 



S7.1 



SCOPE 



This supplement provides general requirements 
that apply to repairs to pressure relief valves. 
Repairs may be required because of defects 
found during periodic inspections because 
testing has identified that valve performance 
does not meet the original code of construction 
requirements, failure during operation, or for 
routine preventative maintenance. 



ment of parts found to be defective, 
reassembly, testing as required by 4.5, 
sealing and application ol a repair 
nameplate. When completed, the 
valve's condition and performance shall 
be equivalent to the standards for new 
valves. 

The administrative requirements for 
National Board Accreditation apply 
only to valves that are stamped with an 
ASME "V," "UV," or "NV" Code symbol 
or marked with an ASME "HV" symbol 
and have been capacity certified on 
the applicable fluid by the National 
Board. 



S7.2 



GENERAL REQUIREMENTS 



a) Repair of a pressure relief valve is consid- 
ered to include the disassembly, replace- 
ment, re-machining, or cleaning of any 
critical part, lapping of a seat and disc, re- 
assembly, adjustment, testing, or any other 
operation that may affect the flow passage, 
capacity, function, or pressure-retaining 
integrity. 

b) Conversions, changes, or adjustments af- 
fecting critical parts are also considered re- 
pairs. The scope of conversions may include 
changes in service fluid and changes such 
as bellows, soft seats, and other changes 
that may affect Type/Model number pro- 
vided such changes are recorded on the 
document as required for a quality system 
and the repair nameplate. (Sec 5.9.1). 

c) The scope of repair activities shall not in- 
clude changes in ASME Code status. 

d) When a repair is being performed under 
the administrative requirements for Na- 
tional Board Accreditation, a repair shall 
consist of the following operations as a 
minimum: 

T) Complete disassembly, cleaning, and 
inspection of parts, repair or replace- 



S7.3 WELD REPAIRS TO PRESSURE 

RELIEF VALVE PARTS 

a) The quality system manual may include 
controls for the "VR" Certificate Holder to 
have the pressure relief valve part repaired 
by a National Board "R" Certificate Holder, 
per this Supplement provided the follow- 
ing documentation is provided to the "R" 
Certificate Holder: 

1 ) Code of Construction, year built; 

2) Part identification; 

3) Part material specified; and 

4) "VR" Certificate Holder's unique identi- 
fier for traceability as required by the 
Repair Inspection Program. 

b) Prior to performing weld repairs to pressure 
relief valve (PRV) parts, the "R" Certificate 
Holder shall receive repair information 
required by Supplement S7.3(a) from the 
"VR" Certificate Holder responsible for the 
pressure relief valve repair. 

1) PRV part weld repairs shall be per- 
formed under the "R" Certificate 
Holder's quality system; however, the 



1 95 



NATIDNAL BOARD INSPECTION CODE • PART 3 



REPAIRS AND ALTERATIONS 



requirements for in-process involve- 
ment of the Inspector (see 1.3.2) maybe 
waived. The requirement for stamping 
is waived. 

2) The process of identifying and con- 
trolling repairs shall be documented 
in the "R" Certificate Holder's quality 
system. 

3) PRV part repairs shall be documented 
on a Form R-1 with a statement under 
Remarks "PRV Part Repair." The owner's 
name and location of installation shall 
be that of the "VR" Certificate Holder. 
The information received from the 
"VR" Certificate Holder as required 
in Supplement S7.3(a) shall be noted 
under "Description of Work." 

4) Upon completion of the repair, the 
repaired part and completed Form R-1 
shall be returned to the "VR" Certificate 
Holder responsible for completing the 
PRV repair. 



b) Critical parts not fabricated by the valve 
manufacturer shall be supplied with mate- 
rial test certification for the material used 
to fabricate the part. 

c) Replacement critical parts receiving records A07 
shall be attached or be traceable to the 
valve repair document (see S7.3 [a]). These 
records shall conform to at least one of the 
following. 

1) Receiving records documenting the A07 
shipping origin of the part fabricated by 

the valve manufacturer (such as pack- 
ing list) from the valve manufacturer or 
assembler of the valve type. 

2) A document prepared by the "VR" A07 
Certificate holder certifying that the 
replacement part used in the repair 

has the manufacturer's identification 
on the part or is otherwise labeled or 
tagged by the manufacturer and meets 
the manufacturer's acceptance criteria 
(e.g., critical dimensions found in main- 
tenance manual). 



S7.4 MATERIALS FOR PRESSURE 

RELIEF DEVICES 

The materials used in making repairs shall con- 
form to the requirements of the original code 
of construction. The "VR" Certificate Holder is 
responsible for verifying identification of exist- 
ing materials from original data, drawings, or 
unit records and identification of the materials 
to be installed. 



S7.5 REPLACEMENT PARTS FOR 

PRESSURE RELIEF DEVICES 

a) Critical parts shall be fabricated by the 
valve manufacturer or to the manufacturer's 
specifications. Critical parts are those that 
may affect the valve flow passage, capacity, 
function, or pressure-retaining integrity. 



3) Receiving records for replacement criti- A07 
cal parts obtained from a source other 
than the valve manufacturer or assem- 
bler of the valve type shall include a 
Certificate of Compliance that provides 
as a minimum: 

a. The part manufacturer and part A07 
designation. 

b. A certifying statement that either: A07 

1 . The part was fabricated by the 
valve manufacturer and meets 
the manufacturer's acceptance 
criteria (e.g., critical dimen- 
sions found in maintenance 
manual), or 



2. The part meets the manu- 
facturer's specifications and 
was fabricated from material 
as identified by the attached 
material test report. 



A07 



1 96 



NATIONAL BOARD INSPECTION CODE • PART 3 



REPAIRS AND ALTERATIONS 



A07 c. The signature of an authorized in- 

dividual of the part source. 

A07 d. The name and address of the part 

source for whom the authorized 
individual is signing. 

d) Material for bolting shall meet the manu- 
facturer's specification, but does not require 
material test certification if marked as re- 
quired by the material specification. 



S7.6 INITIAL ADJUSTMENTS TO 

PRESSURE RELIEF VALVES 

The initial installation testing and adjustments 
of a new pressure relief valve on a boiler or 
pressure vessel are not considered a repair if 
made by the manufacturer or assembler of the 
valve. 



audits of the work carried out in the field shall 
be performed to ensure that the requirements of 
the certificate holder's quality system arc met. 
The audit shall include, but not be limited to, 
performance testing, in accordance with 4.5, 
of valve(s) that were repaired in the field. The 
audits shall be documented. 



S7.9 USE OF OWNER-USER 

PERSONNEL 

For the repair of pressure relief valves at an 
owner-user's facility for the owner-user's own 
use, the "VR" Certificate Holder may utilize 
owner-user personnel to assist certificate holder 
technician(s) in the performance of repairs 
provided: 

a) The use of such personnel is addressed in 
the "VR" Certificate Holder's quality sys- 
tem; 



S7.7 



FIELD REPAIR 



Repair organizations may obtain a "VR" Cer- 
tificate of Authorization for field repair, either 
as an extension to their in-shop/plant scope, or 
as a field-only scope, provided that: 

a) Qualified technicians in the employ of the 
certificate holder perform such repairs; 

b) An acceptable quality system covering 
field repairs, including field audits, is main- 
tained; 

c) Functions affecting the quality of the re- 
paired valves are supervised from the ad- 
dress of record where the "VR" certification 
is issued. 



b) The owner-user personnel are trained and 
qualified in accordance with Supplement 
S7.10; 

c) Owner-user personnel work under direct 
supervision and control of the "VR" Cer- 
tificate Holder's technician(s) during any 
stage of the repair when they are utilized; 

d) The "VR" Certificate Holder shall have the 
authority to assign and remove owner-user 
personnel at its own discretion; and 

e) The names of the owner-user personnel 
utilized are recorded on the document as 
required for a quality system. 



S7.8 



AUDIT REQUIREMENTS 



Upon issuance of a Certificate of Authorization, 
provided field repairs are performed, annual 



1 97 



NATIONAL BOARD INSPECTION CODE • PART 3 — REPAIRS AND ALTERATIONS 



S7.10 GUIDETO JURISDICTIONS FOR 

AUTHORIZATION OF OWNERS- 
USERS TO MAKE ADJUSTMENTS 
TO PRESSURE RELIEF VALVES 



S7.10.1 GENERAL 

The Jurisdiction may authorize properly trained 
and qualified employees of boiler and pressure 
owners-users or their designees to restore set 
pressure and/or performance of pressure relief 
valves. All external adjustments shall be re- 
sealed with a seal identifying the responsible 
organization and a metal tag that identifies the 
organization and the date the adjustment shall 
be installed. 



S7.10.2 TRAINING 

a) The user shall establish a documented in- 
house training program. This program shall 
establish training objectives and provide a 
method of evaluating the training effective- 
ness. As a minimum, training objectives for 
knowledge level shall include: 

1) Applicable ASMF Code and NBIC re- 
quirements; 

2) Responsibilities within the organiza- 
tion's quality system; 

3) Knowledge of the technical aspects and 
mechanical skills for making set pres- 
sure and/or blowdown adjustments to 
pressure relief valves; 

4) Knowledge of the technical aspects and 
mechanical skills for marking of pres- 
sure relief valve adjustments. 

b) If the user established a designee, the des- 
ignee shall establish a training program and 
make their documentation available to the 
user and the jurisdictional authority. 



S7.10.3 DOCUMENTATION 

Each user shall document the evaluation and 
acceptance of an employee's or designee's 
qualifications. 



S7.10.4 QUALITY SYSTEM 

a) A written quality system shall be estab- 
lished by either the user or the designee 
with a written description available to the 
jurisdictional authority. 

b) The written description shall include at a 
minimum: 

1) Calibration of Test Equipment: This 
shall describe a system for the calibra- 
tion of measuring and test equipment. 
Documentation of these calibrations 
shall include the standard used and 
the results. Calibration standards shall 
be calibrated against the equipment 
having valid relationships to nationally 
recognized standards. 

2) Valve Testing, Setting, and Sealing: This 
system shall include provisions that 
each valve shall be tested, set, and all 
external adjustments sealed according 
to the requirements of the applicable 
ASME Code Section and S7.10.1(a). 

3) Valve Marking: An effective marking 
system shall be established to ensure 
proper marking of the metal tag re- 
quired by S7.10.1(a). The written qual- 
ity system shall include a description 
of drawing of the metal tag. 



S7.10.5 EXTERNAL ADJUSTMENTS 

Only external adjustments to restore the re- 
quired set pressure and/or performance of a 
pressure relief valve shall be made under the 
provisions of S7.10.1 . 



1 9B 



NATIONAL BOARD INSPECTION CODE • PART 3 



REPAIRS AND ALTERATIONS 



S7.10.6 REPAIRS 

If disassembly, change of set pressure, or ad- 
ditional repairs are necessary, the valve shall 
be repaired by an organization that meets the 
requirements of the NBIC. 



S7.11 TRAINING AND 

QUALIFICATION OF 
PERSONNEL 



S7.11.1 GENERAL 



S7.11.2 CONTENTS OF TRAINING 
PROGRAM 



relate to pressure relief valve repair. Fach repair 
organization shall document the evaluation and 
acceptance of an individual's qualification for 
the applicable position. 



S7.11.4 ANNUAL REVIEW OF 
QUALIFICATION 

The repair organization shall annually review 
the qualifications of repair personnel to verify 
proficiency as well as compliance with the 
certificate holder's quality system. This review 
shall include training records, documented 
evidence of work performed, and when neces- 
sary, monitoring job performance. The review 
shall be documented. 



A08 The repair organization shall establish a 
documented in-house training program. This 
program shall establish training objectives and 
provide a method of evaluating training effec- 
tiveness. As a minimum, training objectives for 
knowledge level shall include: 

A08 a) Applicable ASME Code and NBIC re- 
quirements; 

A08 b) Responsibilities within the organiza- 
tion's quality system; and 

A08 c) Knowledge of the technical aspects and 
mechanical skills for the applicable 
position held. 



A08 



S7.11.3 QUALIFICATION OF 

PERSONNEL 

Each repair organization shall establish mini- 
mum qualification requirements for those posi- 
tions within the organization as they directly 



S7.12 WELDING FOR PRESSURE 

RELIEF VALVES 

a) Welding shall be performed in accordance 
with the requirements of the original code 
of construction used for the pressure relief 
valve. 

b) Cast iron and carbon or alloy steel having 
a carbon content of more than 0.35% shall 
not be welded. 

c) Defects in pressure relief valve parts such 
as cracks, pits, or corrosion that will be 
repaired by welding shall be completely 



1 99 



NATIONAL BOARD INSPECTION CODE • PART 3 



REPAIRS AND ALTERATIONS 



removed before the weld repair of the part 
is performed. Removal of the defect shall 
be verified by suitable NDE as required. 

d) Consideration shall be given to the condi- 
tion of the existing material, especially in 
the weld preparation area. 



S7.12.1 WELDING PROCEDURE 
SPECIFICATIONS 

Welding shall be performed in accordance 
with Welding Procedure Specifications (WPS) 
qualified in accordance with the original code 
of construction. When this is not possible or 
practicable, the WPS may be qualified in ac- 
cordance with Section IX of the ASME Code. 



S7.12.2 STANDARD WELDING 

PROCEDURE SPECIFICATIONS 

A "VR" Certificate Holder may use one or more 
applicable Standard Welding Procedure Speci- 
fications shown in 2.3 of this part. 



57.12.3 PERFORMANCE 
QUALIFICATION 

Welders or welding operators shall be qualified 
for the welding processes that are used. Such 
qualification shall be in accordance with the 
requirements of the original code of construc- 
tion or Section IX of the ASME Code. 

57.12.4 WELDING RECORDS 

The "VR" Certificate Holder shall maintain a 
record of the results obtained in welding proce- 
dure qualifications, except for those qualifica- 
tions for which the provisions of Supplement 
S7.12.2 are used, and of the results obtained 
in welding performance qualifications. These 
records shall be certified by the "VR" Certificate 
Holder and shall be available to the National 
Board. 



S7.12.5 WELDERS' IDENTIFICATION 

The "VR" Certificate Holder shall establish a 
system for the assignment of a unique identifi- 
cation mark to each welder/welding operator 
qualified in accordance with the requirements 
of the NBIC. The "VR" Certificate Holder shall 
also establish a written procedure whereby 
welded joints can be identified as to the welder 
or welding operator who made them. This 
procedure shall use one or more of the fol- 
lowing methods and shall be described in the 
quality control system written description. The 
welder's or welding operator's identification 
mark may be stamped (low stress stamp) adja- 
cent to welded joints made by the individual, 
or the "VR" Certificate Holder may keep a 
documented record of welded joints and the 
welders or welding operators used in making 
the joints. 



S7.12.6 WELDERS' CONTINUITY 

The performance qualification of a welder or 
welding operator shall be affected when one 
of the following conditions occur: 

a) When the welder or welding operator has 
not welded using a specific process during 
a period of six months or more, their quali- 
fications for that process shall expire. 

b) When there is specific reason to question 
their ability to make welds that meet the 
specification, the qualification that sup- 
ports the welding that is being performed 
shall be revoked. All other qualifications 
not questioned remain in effect. 



S7.13 



HEAT TREATMENT 



S7.13.1 PREHEATING 

Preheating may be employed during welding to 
assist in completion of the welded joint (2.5.1 of 



2DO 



NATIONAL BOARD INSPECTION CODE • PART 3 



REPAIRS AND ALTERATIONS 



this part). The need for and the temperature of 
preheat are dependent on a number of factors, 
such as chemical analysis, degree of restraint 
of the items being joined, material thickness, 
and mechanical properties. The welding pro- 
cedure specification for the material being 
welded shall specify the preheat temperature 
requirements. 



S7.13.2 POSTWELD HEAT TREATMENT 

Postweld heat treatment shall be performed as 
required by the original code of construction 
in accordance with a written procedure. The 
procedure shall contain the parameters for 
postweld heat treatment. 



S7.14.2 SPRING-LOADED PRESSURE 
RELIEF VALVES 

Prior to removal of a valve from a system for 
a repair or any disassembly, ensure that all 
sources of pressure have been removed from 
the valve. 

a) Visual Inspection as Received 

1) This information is to be recorded: 

a. Record user (customer) identifica- 
tion number. 

b. Complete nameplate data, plus 
any important information received 
from customer. 



S7.14 RECOMMENDED PROCEDURES 

FOR REPAIRING PRESSURE 
RELIEF VALVES 



S7.14.1 INTRODUCTION 

a) It is essential that the repair organization 
establish basic, specific procedures for 
the repair of pressure relief valves. The 
purpose of these recommended proce- 
dures is to provide the repair organization 
with guidelines for this important aspect 
of valve repair. It is realized that there are 
many types of valves and conditions under 
which they are repaired and, for this reason, 
the specific items in these recommended 
procedures may not apply, or they may be 
inadequate for each of those types or to 
the detailed repairs that may be required 
for each valve. 

b) S7.1 4.2 contains recommended procedures 
for the repair of spring-loaded pressure 
relief valves, and S7.14.3 contains recom- 
mended procedures for the repair of pilot 
operated types of safety relief valves. 



c. Check external adjustment seals for 
warranty repair. 

d. Check bonnet for venting on bel- 
low-type valves. 

e. Check appearance for any unusual 
damage, missing, or misapplied 
parts. 

2) If sufficient damage or other unusual 
conditions are detected that may pose 
a safety risk during preliminary testing, 
then proceed directly to S7.14.2 c). /^og 

3) Valves that are to be repaired in place 
proceed to S7.14.2 c), unless prelimi- A08 
nary testing has been authorized by the 
owner. 

b) Preliminary Test as Received 

1) Information from the recommended 
preliminary performance test and sub- 
sequent disassembly and inspections 
will provide a basis for any repair in- 
terval change that should be necessary 



2D i 



NATIONAL BOARD INSPECTION CODE • PART 3 — REPAIRS AND ALTERATIONS 



to ensure that the valve will function as 
intended. 

2) Determine set pressure or Cold Differen- 
tial Test Pressure (CDTP) in accordance 
with manufacturer's recommendations 
and appropriate ASME Code Section. 
Do not allow test pressure to exceed 
1 1 6% of set pressure unless otherwise 
specified by the owner. A minimum of 
three tests is usually required to obtain 
consistent results. 

3) If results do not correlate with field 
performance, then steps to duplicate 
field conditions (fluid and temperature) 
may be necessary. 

4) Record preliminary test results and test 
bench identification data. 

c) Disassembly 

1 ) Remove cap and lever assembly if ap- 
plicable. 

2) Remove release nut assembly, if ap- 
plicable. 

3) Loosen jam nut on adjusting (compres- 
sion) screw. 

4) Record measurement and remove ad- 
justing (compression) screw. 

5) Remove bonnet or yoke. 

6) Remove spring and washers, and tag 
(identify) including upper and lower 
washers, as appropriate. 

7) Remove spindle and disk assembly. 

8) Remove ring pins. 

9) Record measurement and remove 
adjusting rings, nozzle, and guide, as 
applicable. 



d) Cleaning 

1 ) Wire all small parts together and clean 
by means of an abrasive. (Caution: do 
not use a cleaning method that will 
damage the parts.) 

2) Do not clean in a chemical solution ex- 
cept under acceptable circumstances. 

3) Protect seating surfaces and nameplates 
prior to cleaning. 

e) Inspection 

1 ) Check spring for damage such as ero- 
sion, corrosion, cracking, breakage, or 
compression below free height. 

2) Check nozzle for cracks (NDE as ap- 
plicable) or unusual wear. 

3) Check disk assembly for cracks (NDE 
as applicable) or unusual wear. 

4) Check spindle for trueness, bearing 
areas, and thread condition. 

5) Check guide for wear and galling. 

6) Check adjusting ring(s) for worn threads 
and wear. 

7) Check ring pins for bent or broken pin 
and thread condition. 

8) Check bellows, if provided, for pinholes 
and corrosion. 

9) Check flange gasket facings for wear 
and cuts. 

f) Machining 

Machine nozzle and disk as necessary 
to the manufacturer's critical dimension 
charts. 



ZDZ 



NATIDNAL BOARD INSPECTION CDDE • PART 3 — REPAIRS AND ALTERATIONS 



FIGURE S8.4-a 

Recommended Test Vesse! Size, Test Medium: Steam 



300 



250 



>00 



150 



100 



50 



32.3 



64.. 



Valve Flow Area (sq. cm) 
96.7 129 161.3 



193 









A 












■£■/ 


/ 




y^ 






\ 


£x 




jt 






/ 


z' 


S mO°>--' 






/ 


/ / 



























10 15 20 

Valve Flow Area (sq. in. 



30 



6 

■5 -=■ 
v 

N 

in 

4 — 



FIGURE S8.4-b 

Recommended Test Vessel Size, Test Medium: Air or Gas 



■J-. 



200 



150 



100 



50 



64.!! 



Valve Tlovv Area (sq. cm) 
96.7 129 161.3 



I93.. c 

























x^^ 


m 










^J^ 

^:^^^\ 








^^- 


^^ 


^--"""^ 








■ — •"" 















10 15 20 

Valve Tlow Area (sq. in.) 



4 D 



2D9 



NATIONAL BOARD INSPECTION CDDE • PART 3 



REPAIRS AND ALTERATIONS 



SUPPLEMENT 9 

PROCEDURES TO EXTEND THE 
"VR" CERTIFICATE OF 
AUTHORIZATION AND STAMP 
TO ASME "NV" STAMPED 
PRESSURE RELIEF DEVICES 



S9.1 



INTRODUCTION 



Approval to extend the scope of the National 
Board "VR" Certificate of Authorization to the 
Certificate Holder to use the "VR" stamp on 
ASME Code "NV" Class 1 , 2, or 3 stamped pres- 
sure relief devices, which have been capacity 
certified by the National Board, may be given 
subject to the provisions that follow. 



S9.2 



ADMINISTRATIVE PROCEDURES 



a) The repair organization shall hold a valid 
"VR" Certificate of Authorization. 

b) The repair organization shall obtain a Na- 
tional Board "NR" Certificate of Authoriza- 
tion and stamp. The requirements for said 
certificate and stamp include, but are not 
limited to, the following. The repair orga- 
nization shall: 

1) Maintain a documented quality assur- 
ance program that meets the applicable 
requirements of 1 .8. This program shall 
also include all the applicable require- 
ments for the use of the "VR" stamp; 

2) Have a contract or agreement with an 
Inspection Agency to provide inspec- 
tion of repaired "NV"-stamped pressure 
relief devices by Inspectors who have 
been qualified in accordance with the 
requirements of ASME QAI-1, Qualifi- 
cations for Authorized Inspection; 

3) Successfully complete a survey of 
the quality assurance program and 
its implementation. This survey shall 



be conducted by representatives of 
the National Board, the Jurisdic- 
tion wherein the applicant's repair 
facilities are located, and the applicant's 
Authorized Inspection Agency. Further 
verification of such implementation by 
the survey team may not be necessary if 
the applicant holds a valid ASME "NV" 
certificate and can verify by documen- 
tation the capability of implementing 
the quality assurance program for repair 
of "NV"-stamped pressure relief de- 
vices, covered by the applicant's ASME 
"NV" certificate. 

c) The application of the "NR" Certificate of 
Authorization and stamp shall clearly de- 
fine the scope of intended activities with 
respect to the repair of Section III, "NV"- 
stamped pressure relief devices. 

d) Revisions to the quality assurance program 
shall be acceptable to the Authorized Nu- 
clear Inspector Supervisor and the National A08 
Board before being implemented. 

e) The scope of the " VR" Certificate of Authori- 
zation shall include repair of "NV"-stamped 
pressure relief devices. 

f) Verification testing of valves repaired by the 
applicant shall not be required provided 
such testing has been successfully com- 
pleted under the applicant's "VR" certifica- 
tion program. 

g) A survey of the applicant for the "VR" Cer- 
tificate of Authorization and endorsement of 
the repair of "NV"-stamped pressure relief 
devices may be made concurrently. 



S9.3 



GENERAL RULES 



a) ASME Code Section III, "NV"-stamped 
pressure relief devices, which have been 
repaired in accordance with these rules, 
shall be stamped with both the "VR" and 
"NR" stamps. 



Z 1 D 



NATIONAL BOARD INSPECTION CODE • PART 3 — REPAIRS AND ALTERATIONS 



b) The "VR" and "NR" slamps shall be applied 
only to "N'.V" stamped (Class 1, 2, or 3) 
National Board capacity certified pressure 
relief devices that have been disassembled, 
inspected, and repaired as necessary, such 
that the valves' condition and performance 
are equivalent to the standards for new 
valves. 

c) All measuring and test equipment used in 
the repair of pressure relief devices shall be 
calibrated against certified equipment hav- 
ing known valid relationships to nationally 
recognized standards. 

d) Documentation of the repair of "NV"- 
stamped pressure relief devices shall be 
recorded on the National Board Form NVR- 
1 , Report of Repair/ Replacement Activities 
for Nuclear Pressure Relief Devices, in ac- 
cordance with the requirements of 1.8 of 
this part. 

e) When an ASME "NV"-stamped pressure 
relief device requires a duplicate nameplate 
because the original nameplate is illegible 
or missing, it may be applied using the 
procedures of 5.9. 5 provided concurrence 

A08 is obtained from the Authorized Nuclear 
Inspector and Jurisdiction. In this case the 
nameplate shall be marked "SEC. Ill" to in- 
dicate the original ASME Code stamping. 



2 i i 



NATIONAL BOARD INSPECTION CODE • PART 3 — REPAIRS AND ALTERATIONS 



Z 1 2 




Part 3, Section V 

Repairs and Alterations — 

NBIC Policy For Metrication 



2 1 3 



NATIONAL BOARD INSPECTION CODE • PART 3 



REPAIRS AND ALTERATIONS 



PART 3, SECTION 7 
REPAIRS AND ALTERATIONS — NBIC POLICY FOR METRICATION 



7.1 



GENERAL 



This policy provides guidance for the use of U.S. 
customary units and metric units. Throughout 
the NBIC, metric units are identified and placed 
in parentheses after the U.S. customary units 
A08 referenced in the text and associated tables. In 
Supplement 6, Continued Service and Inspec- 
tion of DOTTransport Tanks the metric units are 
shown first with U.S. customary units shown 
in parentheses. For each repair or alteration 
performed, selection of units shall be based on 
the units used in the original code of construc- 
tion. For example, items constructed using U.S. 
customary units shall be repaired or altered 
using U.S. customary units. The same example 
applies to items constructed using metric units. 
Whichever units are selected, those units are to 
be used consistently throughout each repair or 
alteration. Consistent use of units includes all 
aspects of work required for repairs or altera- 
tions (i.e. materials, design, procedures, testing, 
documentation, and stamping, etc.). 



Therefore, within the NBIC, metric equivalent 
units are primarily hard conversions. 

The following examples are provided for further 
clarification and understanding of soft conver- 
sions versus hard conversions: 

Example 1: Using 1 in. = 25.4 mm; 
12 in. = .-$04.8 mm (soft conversion) 

Example 2: Using the above conversion, a hard 
conversion may be 300 mm or 305 mm de- 
pending on the degree of precision needed. 



7.3 PROCEDURE FOR 

CONVERSION 

The following guidelines shall be used to con- 
vert between US customary units and metric 
units within the text of the NBIC: 

a) All US customary units will be converted 
using a soft conversion. 



7.2 



EQUIVALENT RATIONALE 



The rationale taken to convert metric units 
and US customary units involves knowing the 
difference between a soft conversion and a 
hard conversion. A soft conversion is an exact 
conversion. A hard conversion is simply per- 
forming a soft conversion and then rounding 
off within a range of intended precision. When 
values specified in the NBIC are intended to 
be approximate values, a hard conversion is 
provided. If an exact value is needed to main- 
tain safety or required based on using good 
engineering judgment, then a soft conversion 
will be used. In general, approximate accuracy 
is acceptable for most repairs or alterations 
performed using the requirements of the NBIC. 



b) Soft conversion calculations will be re- 
viewed for accuracy. 

c) Based on specified value in the NBIC, an 
appropriate degree of precision shall be 
identified. 

d) Once the degree of precision is decided, 
rounding up or down may be applied to 
each soft conversion in order to obtain a 
hard conversion. 

e) Use of hard conversion units shall be used 
consistently throughout the NBIC wherever 
soft conversions are not required. 

Note: Care shall be taken to minimize 
percentage difference between units. 



2 1 4 



NATIONAL BOARD INSPECTION CODE • PART 3 



REPAIRS AND ALTERATIONS 



7.4 



REFERENCING TABLES 



The following tables are provided for guidance 
and convenience when converting between US 
customary units and metric units. See Tables 
7.4-1 through 7.4-8. 

Temperature shall be converted to within 1°C 
as shown in Table 7.4-2. 



TABLE 7.4-1 

Soft Conversion Factors 

(US x Factor = Metric) 


US Customary 


Metric 


Factor 


in. 


mm 


25.4 


ft. 


m 


0.3048 


in.' 


mm 2 


645.16 


ft. 2 


m 2 


0.09290304 


in.-' 


mm' 


16,387.064 


ft. 3 


m 3 


0.02831685 


US gal. 


m 1 


0.003785412 


US gal. 


liters 


3.785412 


psi 


MPa 


0.0068948 


psi 


kRa 


6.894757 


ft-lb 


J 


1.355818 


°F 


°C 


5/9 x (°F 32) 


R 


K 


5/9 


Ibm 


kg 


0.4535924 


lb] 


N 


4.448222 


in.-lb 


N-mm 


112.98484 


ft.-lb 


N-m 


1.3558181 


ksiVin 


Mt'aVm 


1.0988434 


Btu/hr 


VV 


0.2930711 


lb/ft' 


kg/nr 


16.018463 


in.-wc 


kPa 


0.^49089 


Note: The actual pressure corresponding to the height 
of a vertical column of fluid depends on the local 
gravitational field and the density of the fluid, which 
in turn depends upon the temperature. This conver- 
sion factor is the conventional value adopted by ISO. 
The conversion assumes a standard gravitational field 
(g n - 9.80665 N/kg) and a density of water equal to 
1,000 kg/m 3 . 



Fractions of an inch shall be converted accord- 
ing to Table 7.4-3. Even increments of inches 
are in even multiples of 25 mm. For example, 
40 inches is equivalent to 1000 mm. Interme- 
diate values may be interpolated rather than 
converting and rounding to the nearest mm. 

For nominal pipe sizes, the following relation- 
ships were used as shown in Table 7.4-4. 

Areas in square inches (in 2 ) were converted 
to square mm (mm 2 ) and areas in square feet 
(ft 2 ) were converted to square meters (m 2 ). See 
examples in Tables 7.4-5a and 7.4-5b. 

Volumes in cubic inches (in. 3 ) were converted 
to cubic mm (mm 3 ) and volumes in cubic feet 
(iV) were converted to cubic meters (nr). See 
examples in Tables 7.4-6a and 7.4-6b. 

Although the pressure should always be in MPa 
for calculations, there are cases where other 
units are used in the text. For example, kPa is 
used for small pressures. Also, rounding was to 
two significant figures. See examples in Table 
7.4-7. (Note that 1 4.7 psi converts to 1 01 kPa, 
while 15 psi converts to 100 kPa. While this 
may seem at first glance to be an anomaly, it is 
consistent with the rounding philosophy.) 

Material properties that are expressed in psi 
or ksi (e.g., allowable stress, yield and tensile 



TABLE 7.4-2 
Temperature Equivalents 


Temperature °F 


Temperature °C 


60 


16 


70 


21 


100 


38 


120 


49 


350 


177 


400 


204 


450 


232 


800 


427 


1150 


621 





Z 1 5 



NATIONAL BOARD INSPECTION CODE • PART 3 



REPAIRS AND ALTERATIONS 



strength, elastic modulus) were generally con- 
verted to MPa to three significant figures. See 
example in Table 7.4-8. 

An often seen metric pressure rating is the ex- 
pression BAR, one BAR equals 14.5 psi — to 
convert psi rating to a BAR rating, multiply by 
0.069. 



TABLE 7.4-3 

US Fractions/Metric Equivalents 




Inches 


Millimeters 




1/32 


0.8 


3/64 


1.2 


1/16 


1.5 


3/32 


2.5 


1/8 


3 


5/32 


4 


3/16 


5 


7/32 


5.5 


1/4 


6 


5/16 


8 


3/8 


10 


7/16 


11 


1/2 


13 


9/16 


14 


' 5/8 


16 


11/16 


17 


3/4 


19 


7/8 


22 


1 


25 









TABLE 7.4-4 

Pipe Sizes/Equivalents 




US Customary 
Practice 


Metric Practice 




NPS 1/8 


DN 6 


NPS 1/4 


DN 8 


NPS 3/8 


DN 1 


NPS 1/2 


DN 15 


NPS 3/4 


DN 20 


NPS 1 


DN 25 


NPS 1-1/4 


DN 32 


NPS 1-1/2 


DN40 


NPS 2 


DN 50 


NPS 2-1/2 


DN'65 


NPS 3 


DN80 


NPS 3-1/2 


DN90 


NPS 4 


DN 100 


NPS 5 


DN 125 


NPS 6 


DN 150 


NPS 8 


DN 200 


NPS 10 


DN 250 


NPS 12 


DN 300 


NPS 14 


DN 350 


NPS 16 


DN 400 


NPS 18 


DN450 


NPS 20 


DN500 


NPS 22 


DN 550 


NPS 24 


DN600 


NPS 26 


DN 650 


NPS 28 


DN 700 


NPS 30 


DN 750 


NPS 32 


DN 800 


NPS 34 


DN 850 


NPS 36 


I )N 900 


NPS 38 


DN 950 


NPS 40 


DN 1000 


NPS 42 


DN 1050 


NPS 44 


DN 1100 


NPS 46 


DN 1 1 50 


NPS 48 


DN 1200 


NPS 50 


DN 1250 


NPS 52 


DN 1 300 


NPS 54 


DN 1350 


NPS 56 


DN 1 400 


NPS 58 


DN 1450 


NPS 60 


DN 1500 









2 1 6 




Part 3, Section 9 
Repairs and Alterations 
Glossary of Terms 



223 



NATIONAL BOARD INSPECTION CODE ' PART 3 



REPAIRS AND ALTERATIONS 



PART 3, SECTION 9 
REPAIRS AND ALTERATIONS — GLOSSARY OF TERMS 



9.1 



DEFINITIONS 



For the purpose of applying the rules of the 
NBIC, the following terms and definitions shall 
be used herein as applicable to each Part: 

Additional terms and definitions specific to 
DOT Transport Tanks are defined in Part 2, 
Supplement 6. 

A07 Accumulator — A vessel in which the test 
medium is stored or accumulated prior to its 
use for testing. 

Alteration — Any change in the item described 
on the original Manufacturer's Data Report that 
affects the pressure containing capability of the 
pressure-retaining item. Nonphysical changes 
such as an increase in the maximum allowable 
working pressure (internal or external), increase 
in design temperature, or a reduction in mini- 
mum temperature of a pressure-retaining item 
shall be considered an alteration. 

ANSI — The American National Standards 
Institute 

ASME Code — The American Society of Me- 
chanical Engineers' Boiler and Pressure Vessel 
Code published by that Society, including 
addenda and Code Cases, approved by the 
associated ASME Board. 

Assembler — An organization who purchases 
or receives from a manufacturer the necessary 
component parts of valves and assembles, 
adjusts, tests, seals, and ships safety or safety 
relief valves at a geographical location, and 
using facilities other than those used by the 
manufacturer. 

Authorized Inspection Agency — 
New Construction: An Authorized Inspection 
Agency is one that is accredited by the National 
Board meeting the qualification and duties of 



NB-360, Criteria for Acceptance of Authorized 
Inspection Agencies for New Construction. 

Inservice: An Authorized Inspection Agency 
is either: 

a) a jurisdictional authority as defined in 
the National Board Constitution; or 

b) an entity that is accredited by the Na- 
tional Board meeting NB 369, Quali- 
fications and Duties for Authorized 
Inspection Agencies Performing Inser- 
vice Inspection Activities and Quali- 
fications for Inspectors of Boilers and 
Pressure Vessels; NB-371 , Accreditation 
of Owner-User Inspection Organiza- 
tions (OUIO) or NB-390, For Federal 
Inspection Agencies (FIAs) Performing 
Inservice Inspection Activities. 

Capacity Certification — The verification by the 
National Board that a particular valve design or 
model has successfully completed all capacity 
testing as required by the ASME Code. 

Chimney or Stack — A device or means for 
providing the venting or escape of combustion 
gases from the operating unit. 

Conversion — 

Pressure Relief Devices: The change of a pres- 
sure relief valve from one capacity-certified 
configuration to another by use of manufac- 
turer's instructions. 

Units of Measure: Changing the numeric value of 

a parameter from one system of units to another. A07 

Demonstration — A program of maki ng evident 
by illustration, explanation, and completion of 
tasks documenting evaluation of an applicant's 
ability to perform code activities, including the 
adequacy of the applicant's quality program, and 
by a review of the implementation of that program 
at the address of record and/or work location. 



224 



NATIONAL BDARD INSPECTION CODE • PART 3 



REPAIRS AND ALTERATIONS 



Dutchman — Generally limited to tube or pipe 
cross-section replacement. The work necessary 
to remove a compromised section of material 
and replace the section with material meet- 
ing the service requirements and installation 
procedures acceptable to the Inspector. Also 
recognized as piecing. 

Examination — In process work denoting the 
act of performing or completing a task of inter- 
rogation of compliance. Visual observations, 
radiography, liquid penetrant, magnetic par- 
ticle, and ultrasonic methods are recognized 
examples of examination techniques. 

Exit — A doorway, hallway, or similar passage 
that will allow free, normally upright unencum- 
bered egress from an area. 

Field — A temporary location, under the control 
of the Certificate Holder, that is used for repairs 
and/or alterations to pressure-retaining items at 
an address different from that shown on the Cer- 
tificate Holder's Certificate of Authorization. 

Forced-Flow Steam Generator -■■■■ A steam gen- 
erator with no fixed steamline and waterline. 

Inspection — A process of review to ensure 
engineering design, materials, assembly, ex- 
amination and testing requirements have been 
met and are compliant with the Code. 

Inspector — See National Board Commis- 
sioned Inspector and National Board Owner- 
User Commissioned Inspector. 

Intervening — Coming between or inserted 
between, as between the test vessel and the 
valve being tested. 

Jurisdiction — A governmental entity with the 
power, right, or authority to interpret and enforce 
law, rules, or ordinances pertaining to boilers, 
pressure vessels, or other pressure-retaining 
items. It includes National Board member juris- 
dictions defined as "jurisdictional authorities." 

jurisdictional Authority — A member of the 
National Board, as defined in the National 
Board Constitution. 



Lift Assist Device — A device used to apply an 
auxiliary load to a pressure relief valve stem or 
spindle, used to determine the valve set pres- 
sure as an alternative to a full pressure test. 

Manufacturer's Documentation — The docu- 
mentation that includes technical information 
and certification required by the original code 
of construction. 

Mechanical Assembly — The work necessary to A08 
establish or restore a pressure retaining bound- 
ary, under supplementary materials, whereby 
pressure-retaining capability is established 
through a mechanical, chemical, or physical 
interface, as defined under the rules of the 
NBIC. 

Mechanical Repair Method — A method of A08 
repair, which restores a pressure retaining 
boundary to a safe and satisfactory operat- 
ing condition, where the pressure retaining 
boundary is established by a method other 
than welding or brazing, as defined under the 
rules of the NBIC 

NBIC — The National Board Inspection Code 
published by The National Board of Boiler and 
Pressure Vessel Inspectors. 

"NR" Certificate Holder — An organization in 
possession of a valid "NR" Certificate of Autho- 
rization issued by the National Board. 

National Board — The National Board of Boiler 
and Pressure Vessel Inspectors. 

National Board Commissioned Inspector — An 

individual who holds a valid and current Na- 
tional Board Commission. 

Nuclear Items — Items constructed in accor- 
dance with recognized standards to be used in 
nuclear power plants or fuel processing facilities. 

Original Code of Construction — Documents 
promulgated by recognized national standards 
writing bodies that contain technical require- 
ments for construction of pressure-retaining items 
or equivalent to which the pressure-retaining item 
was certified by the original manufacturer. 



225 



NATIONAL BOARD INSPECTION CODE • PART 3 — REPAIRS AND ALTERATIONS 



Owner or User — As referenced in lower case 
letters means any person, firm or corporation 
legally responsible for the safe operation of any 
pressure-retaining item. 

Owner-User Inspection Organization — An 

owner or user of pressure-retaining items that 
maintains an established inspection program, 
whose organization and inspection procedures 
meet the requirements of the National Board 
rules and are acceptable to the jurisdiction or 
jurisdictional authority wherein the owner or 
user is located. 

Owner-User Inspector — An individual who 
holds a valid and current National Board 
Owner-User Commission. 

Piecing ■- A repair method used to remove 
and replace a portion of piping or tubing ma- 
terial with a suitable material and installation 
procedure. 

Pressure-Retaining Items (PRI) —Any boiler, 
pressure vessel, piping, or material used for 
the containment of pressure, either internal or 
external. The pressure may be obtained from 
an external source, or by the application of 
heat from a direct source, or any combination 
thereof. 

Pressure Test — Prior to initial operation, the 
completed boiler, including pressure piping, 
water columns, superheaters, economizers, 
stop valves, etc., shall be pressure tested in a 
test performed in accordance with the original 
code of construction prior to initial operation 
of an installed unit that is witnessed by an 
Inspector. 

Repair — The work necessary to restore pres- 
sure-retaining items to a safe and satisfactory 
operating condition. 

Re-ending -■■-■ A method used to join original 
code of construction piping or tubing with 
replacement piping or tubing material for the 
purpose of restoring a required dimension, 
configuration or pressure-retaining capacity. 

Re-rating — See alteration. 



"R" Certificate Holder — An organization in 
possession of a valid "R" Certificate of Autho- 
ri7ation issued by the National Board. 

Safety Relief Valves — A safety relief valve is 
a pressure relief valve characterized by rapid 
opening or pop action, or by opening in propor- 
tion to the increase in pressure over the opening 
pressure, depending on application. 

Settings — Those components and accessories 
required to provide support for the component 
during operation and during any related main- 
tenance activity. 

Shop — A permanent location, the address that 
is shown on the Certificate of Authorization, 
from which a Certificate Holder controls the 
repair and/or alteration of pressure-retaining 
items. 

Testing Laboratory — National Board accepted 
laboratory that performs functional and capac- 
ity tests of pressure relief devices. 

Transient — An occurrence that is maintained 
only for a short interval as opposed to a steady 
state condition. 

Velocity Distortion — The pressure decrease 
that occurs when fluid flows past the opening 
of a pressure sensing line. This is a distortion 
of the pressure that would be measured under 
the same conditions for a non or slowly mov- 
ing fluid. 

"VR" Certificate Holder — An organization in 
possession of a valid "VR" Certificate of Autho- 
rization issued by the National Board. 

Water Head -The pressure adjustment that 
must be taken into account due to the weight 
of test media (in this case, water) that is 0.433 
psi per vertical ft. (10 kPa per m.) added (sub- 
tracted) from the gage pressure for each foot A07 
the gage is below (above) the point at which 
the pressure is to be measured. 



226 




Part 3, Section 1 D 
Repairs and Alterations — 
NBIC-Apprqved Interpretations 



227 



NATIONAL BOARD INSPECTION CODE • PART 3 — REPAIRS AND ALTERATIONS 

PART 1, SECTION 10 
INSTALLATION — NBIC APPROVED INTERPRETATIONS 



10.1 SCOPE b) Each interpretation references the edition 

and addenda applicable at the time of 
a) This section provides all approved interpre- committee response and approval. Use of 

tations for this edition and all subsequent interpretations for other than approved edi- 

addenda associated with this edition. A tion and addenda may not be appropriate 

complete listed index is provided for refer- for reference. 

ence to previously approved interpretations. 

These previously approved interpretations 

can be found on the National Board Web 

site. 



10.2 !NDEX OF INTERPRETATIONS 

Foreword 95-20 

Code Cases 1923 98-24 

98-56 
1945 98-24 

98-56 

2203 98-12 

Procedure for Obtaining or Renewing a National Board 

Certificate of Authorization 98-21 

07-02 
Outline of Requirements for a Quality System 

for Qualification for the National Board "R" Symbol Stamp 98-13 

General Rules ' 04-02 

Condition of Use 98-02 

Nameplate Contents 98-25 

98-26 

95-26 

Use of Owner-User Personnel During Repairs 01-12 

Test Medium and Testing Equipment 98-1 7 

Procedure for Obtaining or Renewing a National Board 

"NR" Certificate of Authorization 98-07 

98-41 

Interface with the Owner's Repair/Replacement Program 04-1 6 

Prerequisites for Accreditation 98-16 

General Conditions 98-1 1 

Pressure Testing 95-38 

Inspection Interval 98-19 

Conditions that Affect Remaining Lite Evaluation 01-26 

98-03 

95-57 

Operational Inspection 95-55 

Inspection of Parts and Appurtenances 98-09 

228 



NATIONAL BOARD INSPECTION CODE • PART 3 — REPAIRS AND ALTERATIONS 



Restamping or Replacement of Nameplates 98-35 

95-47 

Replacement of Stamped Data 01-13 

General Requirements 04-14 

95-19 

Sco P e 98-22 

Construction Standard 95-36 

95-48 

04-13 
Accreditation 04-13 

Materials 01-28 

Replacement Parts 04-05 

04-06 

04-11 

04-12 

98-14 

98-27 

98-28 

98-37 

95-48 
Welding 01-27 

98-06 

95-51 

07-03 
Nondestructive Examination 04-06 

01-24 

98-10 

95-41 
Acceptance Inspection 04-21 

04-22 
Routine Repairs 04-09 

04-10 

01-19 

01-20 

01-22 

01-23 

98-01 

98-04 

98-18 

98-31 

98-42 

95-27 

95-28 

95-31 

95-33 

95-53 
Examination and Test 04-05 

04-06 
04-11 
98-27 
98-33 
98-36 
95-27 



229 



NATIONAL BOARD INSPECTION CODE • PART 3 — REPAIRS AND ALTERATIONS 



95-32 
95-39 

95-54 

Methods 04 - 0f) 

04-11 

04-20 

01-15 

Documentation 01-29 

95-50 

Repair Plan n1 " 14 

Alterations to ASME Section VIII, Div. 2 04-14 

01-16 

Design 98 " 14 

& 95-22 

04-13 

Calculations 01-17 

Re-Rating 04 " 03 

04-04 

01-11 

98-14 

98-1 5 

98-20 

98-32 

Examination and Test 98-15 

98-34 

98-38 

Methods 04 " 20 

Documentation 01-25 

95-50 

Repair Methods 04 ~ 01 

Scope 98-06 

Welding Method 1 ° 4 ' 12 

Scope 04 " 17 

04-19 

98-08 

Wasted Areas 98 " 42 

Re-Ending or Piecing Pipes or Tubes 98-36 

Patches 04 - 15 

95-52 

Stays 98 " 40 

Re-Rating ° 4 " 18 

Replacement Parts 04 -° 7 

1 04-08 

Stamping and Nameplate Information 95-24 

Glossary of Terms 04-13 

1 95-21 

95-29 

95-34 

95-43 

95-45 



Z3D 



NATIONAL BOARD INSPECTION CODE • PART 3 — REPAIRS AND ALTERATIONS 

National Board Forms 98-39 

95-25 
95-30 
95-40 
95-42 

Examples of Repairs and Alterations 01-21 

98-23 
98-29 
98-30 
95-44 
95-46 
95-48 
95-49 

Repairs 01-18 



23 1 



NATIONAL BOARD INSPECTION CODE • PART 3 — REPAIRS AND ALTERATIONS 



10.3 SUBJECT INDEX OF INTERPRETATIONS 

Acceptance Inspection 04-13 

04-21 
04-22 

Alteration Requirements 04-14 

Alterations to ASME Section VIII, Div. 2 01-16 

Alternatives to PWHT 98-06 

Attachments 98-01 

Blisters, Repair of 98-09 

Calculations 01 -17 

Construction Standards 04-13 

Deaerators, Inspection of 98-09 

Defect Repairs 04-17 

04-19 

Definition of Repair 98-23 

98-29 
98-30 
95-43 
95-45 
95-46 
95-49 

Definition of Alteration 95-21 

95-36 
95-44 
95-45 

Definition of Inspector 95-29 

Definition of Non-Load Bearing 95-33 

Demonstration Requirements 98-41 

De-Rating. 98-20 

Design 04-13 

Deterioration 01-26 

Documentation 01-25 

95-50 

Examination and Test 04-05 

04-06 
04-11 
04-20 

Examples of Repairs and Alterations 01-21 

General Rules 04-02 

04-14 

Inspection Interval 98-19 

95-57 

Joint Review Demonstration Requirements 98-21 

Material Thickness 98-36 

Materials 01-28 

MTR 98-37 

Nameplates 95-24 

Non "U" Stamped Vessels 95-23 

Nondestructive Examination 04-06 

01-24 
98-10 

Nuclear Components 98-07 

Original Code of Construction 95-19 

Z32 



NATIONAL BOARD INSPECTION CODE • PART 3 — REPAIRS AND ALTERATIONS 



Out-of-Service 98-03 

Owner-User Inspection 98-1 1 

98-16 

Owner's Repair/Replacement Program 04-1 6 

Patches 04-15 

Pi P'ng 98-22 

Pressure Relief Valves 98-02 

98-13 

98-17 

98-24 

98-25 

98-26 

95-26 

95-55 

95-56 

07-01 
Pressure Testing 98- 1 5 

98-27 
98-33 
98-34 
98-38 
95-27 
95-32 
95-39 
95-38 

Pressure Testing Repairs 01-15 

Qualification of Welders/Welding Procedures 95-51 

Quality System Manual 98-13 

" R " Forr ™ 98-39 

95-27 

95-28 

95-30 

95-40 

95-42 

95-48 

95-50 
Repair Definition Q4_1 -5 

Repair Methods 04-01 

Repairs .!.."oi.-18 

Repair Plan 01-14 

Reclassification 95-22 

Replacement Nameplates 98-35 

95-47 
Replacement Parts 04-05 

04-06 
04-07 
04-08 
04-11 
04-12 
98-14 
98-27 
98-28 
01-29 
Replacement of Stamped Data 01-13 



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NATIONAL BOARD INSPECTION CODE • PART 3 — REPAIRS AND ALTERATIONS 



Re-Ratine 04-03 

04-04 

04-18 
01-11 
98-14 
98-15 
98-32 

Routine Repairs...: 04-09 

04-10 
01-19 
01-20 
01-22 
01-23 
98-01 
98-04 
98-18 
98-31 
98-42 
95-25 
95-27 
95-28 
95-31 
95-53 
95-54 

Stays • 95-40 

Timing of Repairs 98-05 

5 95-41 

Use of Editions/Addenda 95-20 

Use of Owner/User Personnel During Repairs 01-12 

Welding 01 " 27 

07-03 

Welding Methods 04-06 

04-12 

Window Patch 95-52 



234